Procedure For HACCP Plan

Organization: SPRINTECH
Doc. Title: HACCP Plan Procedure

Document Code: STP/ISP-0 Rev#: 00
INTEGRATED SYSTEM PROCEDURE
HACCP PLAN
(CLAUSE 7.. of ISO 22000:2005)
Name Designation Signature Date
Prepared by: Mr. Mujtaba ISO Coordinator
Reviewed by: Mr. Waqas MR
Approved by: Mr. Mujahid Ali MD
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DOCUMENT HISTORY
REV. PAGE
DATE 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 22
1. 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.
2. 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.
4. Procedure
4.1 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. The team includes:
1. A team leader to convene the group and to direct the work of the team
ensuring that the HACCP concept is properly applied.
2. Members with major role in production of the food packaging material, each
with an understanding of particular food safety hazards and associated risks.
4.2 Describing a product

A full description of the product with relevant safety information is prepared as
given in Appendix II. Also information regarding how the product is to be
packaged, stored and transported is also considered together with facts
regarding it's shelf life and recommended storage temperatures. Labelling
information is also included.
This information will assist the HACCP team to identify 'real' hazards associated
with the process.
4.3 Describing a product’s intended use
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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. This information is
recorded on the same form of product description, see Appendix II.
4.4 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, processing , packaging , storage and
distribution is presented in a detailed flow diagram.
After the flow diagram has been made, a multidisciplinary team will confirm it
on-site during operating hours. Any observed deviation will result in an
amendment of the original flow diagram to make it accurate.
4.5 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.
Food safety hazards for HACCP plan have been classified into three types of
hazards:
1. Biological 2. Chemical 3. Physical
In conducting the hazard analysis, the following should be considered:

a. the likely occurrence of hazards and severity of their adverse health effects
b. the qualitative and/or quantitative evaluation of the presence of hazards
c. survival or multiplication of pathogenic micro-organisms and unacceptable
generation of chemicals in intermediate products, final products, production
line or line environment
d. production or persistence in foods of toxins or other undesirable products of
microbial metabolism, chemicals or physical agents or allergens
e. contamination (or recontamination) of a biological (micro-organisms,
parasites), chemical or physical nature of raw materials, intermediate products
or final products.
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Once a food safety hazard has been identified, then appropriate control measures are
taken into consideration. These are any action or activity that can be used to control
the identified hazard, such that it is prevented, eliminated, or reduced to an acceptable
level.
4.6 Identification of Critical Control Points (CCPs)

The identification of a critical point for the control of a hazard is done by the HACCP
team , according to their judgment , experience and knowledge of the process.
Each process step identified in the flow diagram is considered in sequence. The team
will determine whether the hazard can occur at this step, and if so whether control
measures exist. If the hazard can be controlled adequately, and is not best controlled at
another step, and is essential for food safety, then this step is a CCP for the specified
hazard.
The identification of critical control points has two consequences for the HACCP team
which should then:
1. Ensure that appropriate control measures are effectively designed and
implemented.
2. Establish and implement a monitoring system at each critical point.

Production should cease until control measures are available and a CCP is introduced.
4.7 Critical Limits at Critical Control Points

Each control measure associated with a critical control point will give rise to the
specification of critical limits. Critical limits correspond to the extreme values
acceptable with regard to product safety. They separate acceptability from
unacceptability. They are set for observable or measurable parameters which can
demonstrate that the critical point is under control. It should be based on
substantiated evidence that the chosen values will result in process control.
4.8 Monitoring Procedures at Critical Control Points

Monitoring is the mechanism for confirming that critical limits at each CCP are being
met. A frequency of observations or measurements which provides reliable
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information is established.
The procedure describes the methods, the frequency of observations or measurements
and the recording procedure and identify each critical point:
a. who is to perform monitoring and checking,
b. when monitoring and checking is performed,
c. how monitoring and checking is performed.
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.
4.9 Corrective Actions

For each critical control point corrective actions is planned in advance by the
HACCP team, so that they can be taken without hesitation when monitoring indicates
a deviation from the critical limit.
Such corrective action will include:
• Identification of the person(s) responsible for the implementation of the
corrective action,
• Description of means and action required to correct the observed deviation,
• Action to be taken with regard to products that have been manufactured during the
period when the process was out of control,
• Written record of measures taken indicating all relevant information (for example:
date, time, type of action, actor and subsequent verification check).
Monitoring will indicate that preventive measures (checking equipment, checking the
person handling the food packaging material, checking the efficacy of previous
corrective measures, etc.) should have to be taken if corrective actions for the same
procedure have to be taken repeatedly.
4.10 Verification Procedures

The HACCP team should specify the methods and procedures to be used for
determining if the HACCP plan is working correctly. Methods for verification may
include in particular random sampling and analysis, reinforced analysis or tests
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at selected critical points, intensified analysis of intermediate or final products,

surveys on actual condition during storage.
The frequency of verification should be sufficient to confirm that HACCP plan is
working effectively. The frequency of verification shall depend on the characteristics
of the business , the monitoring frequency, the accuracies of the employees, the
number of deviations detected over time and the hazards involved.
Verification procedures include:
• Audits of HACCP and its records,
• Inspection of operations,
• Confirmation that CCPs are kept under control,
• Validation of critical limits,
• Review of deviations and product dispositions; corrective actions taken with regard
to the product.
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. Verification
shall comprise all of the following elements, 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, storage and/or transport activities
• Physical check on the process being monitored
• Calibration of instruments used for monitoring.
Verification is carried out by Management Representative someone other than the
person who is responsible for performing the monitoring and corrective actions.
Where possible, validation activities should include actions to confirm the
efficacy of all elements of the HACCP plan. In case of change, it is necessary to
review the system, to ensure that it is or will be still valid.
Examples of change include:
• change in raw material or in product, processing conditions (factory layout and
environment, process equipment, cleaning and disinfection program),
• change in packaging, storage or distribution conditions,
• change in consumer use,
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• receipt of any information on a new hazard associated with the product.
Where necessary, such a review must result in the amendment of the procedures laid
down. The changes should be fully incorporated into the documentation and
recordkeeping system in order to ensure that accurate up-to-date information is
available.
4.11 Documentation and Record Keeping

HACCP procedures should be documented. 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.
Documents and records should be kept for a sufficient time to allow the competent
authority to audit the HACCP system. Documents should be signed by Management
Representative of the company.
Documentation examples are:
• Hazard analysis;
• CCP determination;
• Critical limit determination;
• Modifications to the HACCP system.
Record examples are:
• CCP monitoring activities;
• Deviations and associated corrective actions;
• Verification activities.
4.12 Training
The Management representative and food safety team leader shall make sure that all
personnel are aware of the hazards identified (if any), the critical points in the
production, storage, transport and/or distribution process and the corrective
measures, the preventive measures and documentation procedures applicable in
the operations of the company.
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4.1 Related Documents

 HACCP Master Plan
 HACCP Plan Validation/Reassessment Checklist
 Corrective & Preventive Action Form
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Figure 1. CCP Decision Tree- Flow Diagram
Page 10 of 22
Figure 2. Manufacturing Process Flow Diagram
Appendix I: Establishing a HACCP Team
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HACCP Team
Facility Name : Sprintech Packaging Date : September 23 , 2014
Team Member Position HACCP Team Role Signature
Syed Mujtaba Ali Production Member/Advisor
Management
Waqas Hassan Advisor
Representative
Usman Shaukat A.M Production Member
Incharge QA/
Yasir Bilal Team Leader
Product Safety
Printing
Imran Ameer Member
Supervisor
Lamination
Tariq Hussain Member
Supervisor
Lamination
Irfan Sheikh Member
Supervisor
Slitting
Khalid Imtiaz Member
Supervisor
Bag Making
Muhammad Hussain Member
Supervisor
Sleeve Making
Waqas Junaid Member
Supervisor
Warehouse
Naveed Khalid Member
Incharge
Dispatch
Nadeem Ahmad Member
Assistant
Maintenance
Kashif Mehmood Member
Engineer
Purchase
Syed Qasim Raza Member
Executive
Page 12 of 22
HACCP Objective
The purpose of the facility HACCP Team is to ensure safe products for our
customers and their consumers. The HACCP Team will evaluate raw materials
and processes to determine Critical Control Points. Critical Control Points will be
monitored as will other points and processes. The team will provide
documented training for the facility. The facility HACCP Plan will be re -
assessed at least annually. Facility management will provide adequate
resources for the implementation and maintenance of the HACCP Program.
Sign-off and Approval
Position Name Signature
Production Syed Mujtaba Ali
Management Representative Waqas Hassan
A.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
Appendix II: Product Description Format
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Product Description & Intended Use

Section: Date:
Product Category Name
Product description:
Biological, Chemical and Physical

Characteristics
Intended Shelf Life & Storage Conditions
Packaging Requirements
Labeling Requirements
Method of Distribution
Intended Use
Page 14 of 22
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)
Validation (Reassessment) due to changes in the raw materials or source of raw materials , product formulation ,
О processing method or system , including computer and their softwares, packaging , finished product distribution
systems or the intended use or the intended consumers of the finished product or type of consumer complaints.
О Annual Validation (Reassessment ) of the HACCP Plan including Hazard Analysis
If “YES” Food Safety Are modifications to the HACCP
Topic YES NO
Describe Implication? system required?
1.Evaluate product and process

Product description
changed, e.g.; intended О О
use, consumer?
Formula changed? О О
Ingredients / Packaging
changed? О О
Any new product
consumption or storage О О
methods?
Any new suppliers? О О
Process flow changed? О О

Equipment / software
changed? О О
Finished product
distribution changed? О О
Other , e.g.; production
volume increased О О
2. Evaluate product / process history
Repeat CCP deviations? О О

Any recent industry recalls
of similar product since О О
last annual
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New or emerging hazards О О

Regulatory Agency
recommendation e.g., О О
guidance
Any confirmed food
safety consumer О О
complaints
3. Evaluate adequacy of CCP’s, critical limits, monitoring, corrective action, CCP verification, and record keeping
procedures. Review current CCP Documentation
Do the CCPs control the

hazards? О О
Are the CPP critical

limits adequate? О О
Do monitoring methods
and frequency О О
demonstrate control?
Do corrective actions
properly address О О
affected product?
Does validation include
review of consumer О О
complaints?
Page 16 of 22
Appendix IV: HACCP Plan Reassessment Change Form
HACCP Plan Reassessment Change Form

Person(s)
Facility Name :
Responsible:
HACCP Plan Name/Number and Date :
During the reassessment of this plan, the person(s) responsible listed above has/have determined that
Changes, Additions, or Deletions were needed. Those changes are documented below. Also attached is
information used to support modification(s) of this plan.
Check One CHANGE ADDITION DELETION
What specifically were Changed / Added / Deleted?
Why was it Changed / Added / Deleted?
What is the basis for the Change / Addition / Deletion?
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Raw Material Hazard Analysis

1 2 3 4 5 6
List each raw Does this material / Is this hazard Is this hazard Identify the last Assign a CCP #
material/ ingredient ingredient CONTROLLED by a ELIMINATED by a process step that when the answer in
in the process INTRODUCE a Pre-requisite subsequent process will eliminate the Column #4 is NO.
potential food Program or process step? potential hazard. (otherwise leave blank)
safety hazard? What step? If YES, this step is NOT a
CCP. Indentify the
is it? If YES, indentify the program
or process. If a pre-requisite subsequent process step in
C =Chemical
program or process is Column 5 and proceed to the
P = Physical
identified, do not complete next process step. If the
B = Biological
Columns 4-6 and go to next hazard is eliminated at this
process step. If NO, go to step, enter NO and go to
column 4. column 6 and assign CCP #.
C No
Films (PET , PVC , BOPP,
HDPE, HTL ,OPP, CPP, P Yes – Foreign Material Yes – Receiving Inspections
LDPE , NYLON PE ) B No
Adhesives C No
(hot melt, resins , P Yes – Foreign Material Yes – Receiving Inspections
lamination) B Yes - Infestation Yes – Receiving Inspections
C Yes – Plant Chemical Yes – Chemical Control Plan
Ink and chemicals P No
B No
Paper , Bleach Board C No

(various types and P Yes – Foreign Material Yes – Receiving Inspections
grades) B Yes - Moulds Yes – Receiving Inspections
C No
Packing Materials P No
Yes – Foreign Materials
B Yes – Receiving Inspections
& Infestation
Page 18 of 22
Process Hazard Analysis

1 2 3 4 5 6
List each raw Do this material / Is this hazard Is this hazard Identify the last Assign a CCP #
material/ ingredient ingredient CONTROLLED by a ELIMINATED by a process step that when the answer in
in the process INTRODUCE a Pre-requisite subsequent process will eliminate the Column #4 is NO.
potential food Program or process step? potential hazard. (otherwise leave blank)
safety hazard? What step? If YES, this step is NOT a
CCP. Indentify the
is it? If YES, indentify the program
or process. If a pre-requisite subsequent process step in
C =Chemical
program or process is Column 5 and proceed to the
P = Physical
identified, do not complete next process step. If the
B = Biological
Columns 4-6 and go to next hazard is eliminated at this
process step. If NO, go to step, enter NO and go to
column 4. column 6 and assign CCP #.
C No
Receiving Inspections P Yes – Foreign Material Yes – Receiving Inspections
B Yes - Infestation Yes – Receiving Inspections
C No
Warehousing P Yes – Foreign Material Yes – Receiving Inspections
B Yes - Infestation Yes – Receiving Inspections
Yes – Incorrect Design Yes – Design checklist
C
Yes – Line Clearance No
No Line Clearance
Printing P No CCP-1
B No
C Yes No No Line Clearance
P No CCP-2
Lamination Solventless
Yes – Contamination / Yes – Personal Hygiene &
B
infestation Housekeeping programs
C Yes No No Line Clearance
P No CCP-3
Lamination Solvent Base
B
C No
Slitting P No
B No
Page 19 of 22
C No No Visual Inspection
Bag Making P No CCP-4
B
C No
Sleeve & Tube Making P No

B
Yes – Incorrect
C No No Visual Inspection and
palletizing (allergen)
Packaging P No pallet control CCP-5
B
C No
Warehousing P No
B
Infestation Housekeeping programs
C No
Dispatch/Shipping P No
B
Page 20 of 22
HACCP Master Plan

HACCP Plan for Multi-layer Flexible Packaging Materials
CPP Critical Monitoring Corrective

Significant Hazard Verification Record(s)
Number Limit What How Frequency Who Action
Printed materials No materials Operator Operator

Verified by
CCP-1 from previous jobs from other removes all removes
Printing Each operator or Production
Line have not been fully jobs allowed materials from Operator materials per
procedure work order other co- Records
Clearance cleared. in area. previous order critical limits
worker
before new job and re-
starts up. inspects line.
Laminated materials No materials Operator Operator
Verified by
Lamination Each operator or
Line have not been fully jobs allowed materials from Operator materials per Production
procedure work order other co-
cleared. in area. previous order critical limits Records
Clearance worker
Laminated materials No materials Operator Operator
Verified by
Lamination Each operator or
Line have not been fully jobs allowed materials from Operator materials per Production
procedure work order other co-
cleared. in area. previous order critical limits Records
Clearance worker
Incorrect unitizing or No mixing of Work Operator Verified by
palletizing due to bags. instructions for removes operator or
CCP-4
inadvertent mixing of Visual operators / Each materials per other co- Production
Visual Operator
bags results in Inspection helpers carton critical limits. worker Records
Inspection allergen risk due to
mixed product types
CCP-5 Incorrect unitizing or No mixing of Visual Work Segregate Verified by
Visual palletizing due to bags. Inspection instructions for affected operator or
Every Production
Inspection inadvertent mixing of coupled with operators/ pallet
Operator pallets. other co- Records
& Pallet bags results in mixed pallet helpers worker
Control product types segregation.
Page 21 of 22
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Procedure For HACCP Plan

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Organization: SPRINTECH

Doc. Title: HACCP Plan Procedure

INTEGRATED SYSTEM PROCEDURE

Name Designation Signature Date

Prepared by: Mr. Mujtaba ISO Coordinator

Reviewed by: Mr. Waqas MR

Approved by: Mr. Mujahid Ali MD

4.2 Describing a product

4.3 Describing a product’s intended use

4.4 Construction of Flow Diagram ( Description of Manufacturing process)

4.5 Identification and Analysis of Hazard(s)

1. Biological 2. Chemical 3. Physical

In conducting the hazard analysis, the following should be considered:

4.6 Identification of Critical Control Points (CCPs)

2. Establish and implement a monitoring system at each critical point.

4.7 Critical Limits at Critical Control Points

4.8 Monitoring Procedures at Critical Control Points

4.9 Corrective Actions

4.10 Verification Procedures

at selected critical points, intensified analysis of intermediate or final products,

• receipt of any information on a new hazard associated with the product.

4.11 Documentation and Record Keeping

4.1 Related Documents

Figure 1. CCP Decision Tree- Flow Diagram

Figure 2. Manufacturing Process Flow Diagram

Appendix I: Establishing a HACCP Team

Team Member Position HACCP Team Role Signature

Syed Mujtaba Ali Production Member/Advisor

Usman Shaukat A.M Production Member

Sign-off and Approval

Position Name Signature

Production Syed Mujtaba Ali

Management Representative Waqas Hassan

A.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

Appendix II: Product Description Format

Product Description & Intended Use

Product Category Name

Biological, Chemical and Physical

Intended Shelf Life & Storage Conditions

Appendix III: HACCP Validation/Reassessment Checklist

HACCP Validation/Reassessment Checklist

1.Evaluate product and process

Any new suppliers? О О

Process flow changed? О О

2. Evaluate product / process history

Repeat CCP deviations? О О

New or emerging hazards О О

Do the CCPs control the

Are the CPP critical

Appendix IV: HACCP Plan Reassessment Change Form

HACCP Plan Reassessment Change Form

Check One CHANGE ADDITION DELETION