Safety Management System Doc. No.

Date:
Rev. No.
HACCP FILE Page: 56 of 69
Originator: Signature:
Approved: Signature:
MANUFACTURING ANALYSIS
CC
Food Safety Risk P
Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
See incoming
Paper B/C/P Incoming prod. 3 2 6 Incoming inspection inspection.   X
See incoming
  B/C/P Bird droppings 3 5 15 Cover Reels inspection.   X
See incoming
  P Glass 3 6 18 Cover Reels inspection.   X

See incoming
  B/C Hyd. Oil 5 3 15 Cover Reels inspection.   X
See incoming
  B/C Pests 2 6 12 Cover Reels inspection. X
Workers dirty See incoming
  P hands 5 3 15 Cover Reels inspection.   X
See incoming
Starch B/C/P Incoming prod. 1 6 6 Incoming sample samples at QA   X
See incoming
  B/C Pests 2 6 12 Sealed inspection.   X
See incoming
Ink P Incoming prod. 1 6 6 Incoming sample samples at QA   X
See incoming
  B/C Pests 2 6 12 Sealed inspection.   X
See incoming
Glue B/P Incoming prod. 1 6 6 Incoming sample samples at QA   X
See incoming
  B/C Pests 2 6 12 Sealed inspection.   X
Receive
d Paper B/C/P Incoming prod. 3 2 6 Incoming inspection Incoming inspections   X
  B/C/P Bird droppings 3 5 15 Inspections/removal See bird sighting   X
  P Glass 3 6 18 Replace and GBP Surveys/Inspections   X

F/L 250 hrs

inspection/daily
  B/C Hyd. Oil 5 3 15 Service/ inspections check sheets   X

Safety Management System Doc. No.

 Date:
Rev. No.
HACCP FILE Page: 57 of 69
Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programm
Step Physical Description Control Measures e Reference Yes No
  B/C Pests 2 6 12 Pest control Ecolab   X
Workers dirty
  P hands 5 3 15 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Corruga
tor                  
Single
Facer B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
  P Glass 3 6 18 Replace and GBP Surveys/Inspections   X
Pragma/Planned
  P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
  P Metal 3 3 9 Inspections/removal maintenance.   X

F/L 250 hrs

inspection/daily
  B/C Hyd. Oil 5 3 15 Service/ inspections check sheets   X
F/L 250 hrs
inspection/daily
  B/C Diesel 2 4 8 Service/ inspections check sheets   X
Pragma/Planned
  B/C/P Lubricants 5 3 15 Inspections/removal maintenance.   X
  B/C/P Pests 2 3 6 Pest control Ecolab   X
Workers dirty
  P hands 4 2 8 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Pragma/Planned
  P Flaking paint 6 3 18 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Condensate 9 2 18 Ventilation maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 5 3 15 Inspection/ cleaning maintenance.   X
Pragma/Planned
  P Rust 5 3 15 Inspections/removal maintenance.   X
Double
Backer B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
 

P Glass 3 6 18 Replace and GBP Surveys/Inspections   X

 Safety Management System Doc. No.
Date:
Rev. No.
HACCP FILE Page: 58 of 69
Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
Pragma/Planned
  P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
  P Metal 3 3 9 Inspections/removal maintenance.   X
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 5 3 15 Service/ inspections check sheets   X
F/L 250 hrs
inspection/daily
  B/C Diesel 2 4 8 Service/ inspections check sheets   X
Pragma/Planned
  B/C/P Lubricants 5 3 15 Inspections/removal maintenance.   X
  B/C/P Pests 2 3 6 Pest control Ecolab   X
Workers dirty
  P hands 4 2 8 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Pragma/Planned
  P Flaking paint 6 3 18 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Condensate 9 2 18 Ventilation maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 5 3 15 Inspection/ cleaning maintenance.   X
Pragma/Planned
  P Rust 5 3 15 Inspections/removal maintenance.   X
Slitter/
Scorer B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
  P Glass 3 6 18 Replace and GBP Surveys/Inspections   X
  P Wood 3 3 9 Inspections/removal Planned maintenance   X
  P Metal 3 3 9 Inspections/removal Planned maintenance   X
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 5 3 15 Service/ inspections check sheets   X

Pragma/Planned
  B/C/P Lubricants 5 3 15 Inspections/removal maintenance.   X
X

  Ecolab  
B/C/P Pests 2 3 6 Pest control
Safety Management System Doc. No.
Date:
 Rev. No.
HACCP FILE Page: 59 of 69

Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programm
Step Physical Description Control Measures e Reference Yes No
Workers dirty
  P hands 4 2 8 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Pragma/Planned
  P Flaking paint 6 3 18 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Condensate 9 2 18 Ventilation maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 5 3 15 Inspection/ cleaning maintenance.   X
Pragma/Planned
  P Rust 5 3 15 Inspections/removal maintenance.   X
Pragma/Planned
Knives P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
  P Metal 3 3 9 Inspection/removal maintenance.   X
Pragma/Planned
  B/C/P Lubricants 7 3 21 Service/ inspections maintenance.   X
  B/C/P Pests 2 6 12 Pest control Ecolab   X
Workers dirty
  P hands 7 3 21 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
X
Pragma/Planned
  P Flaking paint 8 3 24 Inspection/ repaint maintenance.  
Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
                   
Stacker B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
Pragma/Planned
  P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
  P Metal 3 3 9 Inspection/removal maintenance.   X
Pragma/Planned
  B/C/P Lubricants 4 2 8 Service/ inspections maintenance.   X
  B/C/P Pests 2 3 6 Pest control Ecolab   X
X

Workers dirty  
  P hands 3 3 9 Wash facilities Training/enforce

Safety Management System Doc. No.

Date:
 Rev. No.
HACCP FILE Page: 60 of 69

Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programm
Step Physical Description Control Measures e Reference Yes No
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
Pragma/Planned
  P Flaking paint 5 3 15 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 4 3 12 Inspection/ cleaning maintenance.   X
Incoming
Starch B/C/P Incoming prod. 3 2 6 Incoming inspection inspections   X
  B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
Pragma/Planned
  P Glass 3 7 21 Replace and GBP maintenance.   X
Pragma/Planned
  P Metal 3 3 9 Inspection/removal maintenance.   X
  B/C/P Pests 2 3 6 Pest control Ecolab   X
Workers dirty
  P hands 3 3 9 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Pragma/Planned
  P Flaking paint 8 3 24 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 7 3 12 Inspection/ cleaning maintenance. X
Martin Pragma/Planned
1228 P Rust 8 3 24 Planned Maintenance maintenance.   X
Pragma/Planned
Printing P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
Die Cut P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
FFG P Metal 3 3 9 Inspections/removal maintenance.   X
Glue/Ink
F/L 250 hrs
Folding inspection/daily
Section B/C Hyd. Oil 7 3 21 Service/ inspections check sheets   X
  B/C/P Pests 2 6 12 Pest control Ecolab   X
X

Training/enforce

Workers dirty
  P hand 7 3 21 Wash facilities  

Safety Management System Doc. No.

Date:
 Rev. No.
HACCP FILE Page: 61 of 69

Originator: Signature:
Approved: Signature:
CC
Food Safety Risk P
Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
Pragma/Planned
  P Flaking paint 8 3 15 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
  B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
                   
Martin Pragma/Planned
924 P Rust 8 3 24 Planned Maintenance maintenance.   X
Pragma/Planned
Printing P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
Die Cut P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
FFG P Metal 3 3 9 Inspections/removal maintenance.   X
Glue/Ink
F/L 250 hrs
Folding inspection/daily
Section B/C Hyd. Oil 7 3 21 Service/ inspections check sheets   X
  B/C/P Pests 2 6 12 Pest control Ecolab   X
Workers dirty
  P hand 7 3 21 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
X
Pragma/Planned
  P Flaking paint 8 3 15 Inspection/ repaint maintenance.  

Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
  B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X

Safety Management System Doc. No.

Date:
 Rev. No.
HACCP FILE Page: 62 of 69

Originator: Signature:
Approved: Signature:
CC
Food Safety Risk P
Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
Miniline Pragma/Planned
718 P Rust 8 3 24 Planned Maintenance maintenance.   X
Pragma/Planned
Printing P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
Die Cut P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
FFG P Metal 3 3 9 Inspections/removal maintenance.   X
Glue/Ink
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 7 3 21 Service/ inspections check sheets   X
  B/C/P Pests 2 6 12 Pest control Ecolab   X
Workers dirty
  P hand 7 3 21 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
Pragma/Planned
  P Flaking paint 8 3 15 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
  B/C/P Bird droppings 3 6 18 Inspections/removal See bird sighting   X
Pragma/Planned
Klett P Rust 8 3 24 Planned Maintenance maintenance.   X
Compact/Planned
Printing P Glass 3 8 24 Replace and GBP maintenance   X
Pragma/Planned
Die Cut P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
FFG P Metal 3 3 9 Inspections/removal maintenance.   X
Glue/Ink
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 7 3 21 Service/ inspections check sheets   X

  B/C/P Pests 2 6 12 Pest control Ecolab   X

X

 
Training/enforce
 
Workers dirty
P hand 7 3 21 Wash facilities

Safety Management System Doc. No.

Date:
 Rev. No.
HACCP FILE Page: 63 of 69

Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
Pragma/Planned
  P Flaking paint 5 3 15 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
Bird
  B/C/P droppings 3 6 18 Inspections/removal See bird sighting   X
Pragma/Planned
Printing P Rust 8 3 24 Planned Maintenance maintenance.   X
Pragma/Planned
Printing P Glass 3 8 24 Replace and GBP maintenance.   X
Pragma/Planned
Die Cut P Wood 3 3 9 Inspections/removal maintenance.   X
Pragma/Planned
FFG P Metal 3 3 9 Inspections/removal maintenance.   X
Glue/Ink
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 7 3 21 Service/ inspections check sheets   X
  B/C/P Pests 2 6 12 Pest control Ecolab   X
Workers dirty
  P hand 7 3 21 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 Smoking policy Smoking policy   X
  C/P Eating 2 4 8 Eating policy Eating policy   X
Pragma/Planned
  P Flaking paint 5 3 15 Inspection/ repaint maintenance.   X
Pragma/Planned
  B/C/P Poor cleaning 7 3 21 Inspection/ cleaning maintenance.   X
Bird
  B/C/P droppings 3 6 18 Inspections/removal See bird sighting   X
Despatc Out going Truck/trailer
h B/C/P prod. 3 2 6 Out going inspection inspections   X
Bird
  B/C/P droppings 3 5 15 Inspections/removal See bird sighting   X
  P Glass 3 6 18 Replace and GBP Surveys/Inspections   X

Safety Management System Doc. No.

Date:
 Rev. No.
HACCP FILE Page: 64 of 69

Originator: Signature:
Approved: Signature:

Food Safety Risk CCP

Potential

Probability
Hazards

Severity
Biological/ Pre Rec.

Total
Process Chemical/ Programme
Step Physical Description Control Measures Reference Yes No
F/L 250 hrs
inspection/daily
  B/C Hyd. Oil 5 3 15 Service/ inspections check sheets   X
  B/C Pests 2 6 12 Pest control PPCS   X
Workers dirty
  P hands 5 3 15 Wash facilities Training/enforce   X
  C/P Smoking 1 3 3 No Smoking Smoking policy   X
  C/P Eating 2 4 8 No Eating Eating policy   X
Bird
  B/C/P droppings 3 6 18 Inspections/removal See bird sighting   X
  P Wood 3 3 9 Inspections/removal Planned maintenance.   X