Haccp Plant Table Feed Safety Management System: Raw Material

HACCP PLANT TABLE FEED SAFETY MANAGEMENT SYSTEM
RAW MATERIAL
Identifikasi Bahaya Analisa Bahaya (Hazard Analysis) (7.4.3)

(Hazard Identification)
(7.4.2) Bovee Matrix
Keparahan Bahaya Kemungkinan Kejadian Apakah Potensi

(Severity of Hazard) (Probability of Occurance) Bahaya
Tahapan Proses Signifikan
No (Process Step) Alasan
Kategori (Is The (Justification)
Occasionaly
Bahaya Bahaya Potensial Sumber Bahaya Potential
Commonly
Very High
Un-Likely
Probable
(Hazard (Potensial Hazard) (Source of hazard) Hazard
High
Med
Low
Category) Significant)
1 2 3 4 1 2 3 4
1 PFAD Oil receiving Chemical Heavy metal as lead, From Preveous Process v v Not Significant Pb= low, because supplier
cadmium, like WINA is GMP+ and FSSC
mercury & arsenic certified. Also, record over
Contamination through the years shows heavy metal
external sources level is within specifcations
S=high, because of the
combined risks of heavy
PFAD used in Megalac
production.
- Dioxin compounds v v Not Significant Pb = Low because (a)

Because PFAD is positive
released
S = High, because of dioxin is
toxic and carcinogenic
Physical Contamination of foreign From suppliers storage v v Not significant Pb = Medium because
materials such as dust tank. foreign materials like a sand is
dirt and sand. occasionally found
at the VWFII receiving
strainer.
S= Medium because all these

foreign material are trapped
by strainer during
PFAD receiving at VWFII
2 CaO Purchase Physical Metal piece from wear Supplier processing v v Not significant Pb = Medium and S = low.
and receiving and tear of quicklime Because
factory limestone goes through
· Contamination of foreign Magnetic screen before
materials such as dust, processing at supplier factory.
dirt, sand & small stones,
during handling and
transportation
Chemical . Heavy Metal as Lead & v v Not significant Pb & S = Low, because record
Arsenic over the years show heavy
· Contamination through metal level is within
external sources specification
· Part of product
specification
3 BHT Purchase Chemical . Heavy Metal as Lead v v Not significant Pb = Low, because record
and receiving · Contamination through over the years show heavy
external sources metal level is within
· Part of product specification
specification S = low because dosage
added into PFAD is verry
small, i.e. 0.20% only,
supported by COA from
supplier and 3rd party lab
verification once per year by
supplier.
4 Processed Physical rust from pipeline and v v Significant Pb = probable, because pipeline
treated water sand. is using carbon steel (easy to
from utility rust). S = high, because when
consume by animals, it's harmful
to their health.
Biological Mold and microbiology v v Significant Pb = probable, performance

variation of RO treatment plant.
S = medium, bbecause when
consume by animals, it's harmful
to their health.
6 Megalac bag – Physical Foreign material like dust v v Not significant Pb &S = low, moldy pallet
25kg purchase & dirt due to unclean unlikely to be acceptable
(Paper bag) pallets during receiving supplier
delivers pallets in truck with
cover.
7 Megalac bag – Physical Foreign material like dust v v Not significant Pb &S = low, moldy pallet
650kg purchase & dirt due to unclean unlikely to be acceptable
(Jumbo bag) pallets during receiving supplier
delivers pallets in truck with
cover.
8 Wooden pallets Physical Foreign material like dust v v Not significant Pb & S = low, because before
& dirt due to unclean dispatching supplier has already
pallets checked and during receiving
factory, will also checked
Biological Insect and mold v v Not significant Pb & S = low, because

dispatching supplier has already
checked and during receiving
factory, will also checked.
Supplier have ISPM certificate.
Informasi : (K = Kimia, F = Fisika, B = Biologi)

Keterangan:
Persyaratan ISO 22000:2005
1. Klausul 7.4 : Analisa Bahaya
2. Klausul 7.4.2 : Identifikasi Bahaya dan Penentuan Tingkat Yang Dapat Diterima
3. Klausul 7.4.3 : Assesmen / Penilaian Bahaya
4. Klausul 7.4.4 : Seleksi dan Assesmen Tindakan Pengendalian
- Jika bahaya bisa dikendalikan dengan PRP maka tidak perlu dilanjutkan ke decision tree
- Decision tree refer to Codex CAC/RCP 1-1969, Rev.4-2003
Document No. : M-WINA/FSMS/001
Rev. :
Issue Date :
Effective. Date :
Page :
Penentuan CCP
(CCP Determination)
Decision Tree
PRP/ OPRP / CCP

(Based on Codex)
Control Measures Referensi Undang-undang, Standar
*Jika bahaya bisa dikendalikan Industri, dan/atau kontrak perjanjian
dengan PRP maka tidak perlu (Legislation, Industry Standard,
dilanjutkan ke decision tree and/or Contract Terms Reference)
Q1 Q1a Q2 Q3 Q4
General control Y N Y CCP

- Get supply from GMP
equivalent certified supplier
- Periodic heavy metal itest as
verivication
- This control will be exercised
under HACCP plan for process
General Control
- Specify dioxin as part of
the quality specification
-Must have dioxin analysis.
General Control Y N Y oPRP

- Periodic checking of
strainer at PFAD
receiving and record
observation – at least
once in month
Monitor amount of Y PRP
physical material trapped
by screen/ mesh/ filter.
Monitor quality from CoA from Y PRP

supplier and perform heavy metal
test once per month from supplier.
Y PRP
- Periodic Heavy metal
test as verivication, i.e.
at least once per year.
- Monitor CoA from supplier
By using 10 mikron filter bag Y N Y

before water tank.
oPRP
Install UV filter before process Y N Y

water tank.
oPRP
Visual check procedure and CoA Y PRP
from supplier.
Visual check procedure and CoA Y PRP

from supplier.
Visual check procedure. Y PRP
Visual check procedure and Y PRP

ISPM certificate from supplier
for every receiving.
FEED SAFETY MANUAL GMP+B2 Document No. :
CALCIUM SOAP DEPARTEMENT Rev. :
Issue Date :
RAW MATERIAL Effective. Date :
Page :
Bahaya Prosedur Pengawasan (7.6.4)

Batas Kritis Setiap Kegiatan
Titik Kendali Kritis (7.6.2) Signifikan
Pencegahan (7.6.3) (critical limit Verifikasi (verification)*
(critical control point) (significant Tindakan koreksi
every prevention) Apa (what) Bagaimana (how) Frekwensi (frequent) Siapa (who) Koreksi (correction) Rekaman (record)
hazard) (corrective action) (see F/WINA-QA-10-030)
CCP 1 PFAD Heavy metal Pb = 10mg/kg (ppm) Heavy Supplier’s At least once Plant - Hold Entire PFAD Lot In Call HACCP Meeting For FPF(MP) / 008 & 009 for Lab test by 3rd party lab, at
Purchase & as lead (Pb), As = 2mg/kg (ppm) metal as certificate of a year executive / Storage Tank. Draw Course Of Action And monitoring & verivication least once a year
Receiving cadmium Cd = 1 mg/kg (ppm) Pb, As, CD, analysis and / (because past Sales PFAD Samples From Review Supplier Status plan
(Cd), Mercury Hg = 0.1 mg/kg (ppm) & Hg or lab test by result showed manager Tank And Run Relevant
(Hg) & VWFII low Tests. Certificate of analysis by
Arsenic (As) incidence) - Test Megalac Stock In 3rd party lab
(Chemical) Warehouse For Heavy
Metal Through QMQ(PQ)/003 on PFP in
Random Samples. supplier
- Trance Test Result Of management
Megalac to PFAD
- If Megalac’s Heavy
Metal Levels Meet
Standard, No Recall/
Disposal Of End
Products, Despite PFAD
Heavy Metal Out Of
Specs
- Return Contaminate
PFAD (Whole Storage/
Blending Tanks) To
Supplier And Seek
Compensation
Issue Date :
Page :

CCP 1 PFAD Dioxin Dioxin’s Action limit = 0.5 ng Dioxin in Supplier’s Every Supplier & Actions: Call HACCP FPF(Mp)/008 & 009 For Lab test by
Purchase & Receiving (supply of WHOPCDD/FTEQ/kg PFAD certificate of corresponding plant (1) Reject PFAD if (i) meeting for course of Monitoring & Verivication accredited
(continue) positive analysis of the batch Executive / exceed 0.75ng/kg; or action and review Plan 3rd party lab
Released Dioxin’s Rejection limit = 0.75 ng corresponding Sales (ii) Dioxin levei is > 0.6 supplier status
PFAD) WHO-PCDD/FTEQ/kg batch Must have Manager ng/kg but below Certification Verification
Note: access to cert 0.75ng/kg Of Analysis By frequency is
Dioxin Internal accepted Dioxin level = 0.6 of analysis for Accredited 3rd based on
compounds ng WHOPCDD/FTEQ/kg, dioxin before (2) If dioxin level is Party Lab cumulated
Inciude : any delivery between 0.5 to history of an
· Di0xin During emergency case (see of 0.6ng/kg, we can Qmq(Pq)003 supplier.
· Dioxin-like Note** at Corrective Action coloumn corresponding exercise the options of On Pfp In when there
PCBs batch is to be taking (2a) or (2b) Supplier is no history
· Non- arranged management of deviation ,
Dioxin like Action (2a) veruvication
PCBS Dilution with positive FPF(HM)015 is in fact not
Based on releaase PFAD, should PFAD Batch needed
COA results we have access to positive
Over the other batches of Release Verification
years (since positive release PFAD tracking for Action
2012), only with Dioxin level ≤ (2a)
Dioxin is 0.5ng/kg for dilution The diluted
“critical batch can be
hence only The new diluted / verified by
Dioxin is blended batch must laboratory
targeted for have a lower dioxin Dioxin test, if
level. Arrount 0.5ng/kg need to.
or <ng/kg idealy
The new diluted/ If and when
blended batch can be the blending
formula is
verified later
and proof to
be reliable,
the biended
PFAD does
Issue Date :
Page :

released 24 hours after not need to
blending) for be tested for
production use Dioxin again
based on dilution afier
formulation (see blending.
QMQ(SP)/G17), with
the preceding
condition that the
dioxin lavel of the
source PFAD is
known.
Action (2b) Verification

in cases of emergency, for Action
like shortage of PFAD (2b)
in the market or Finished
prolonged delay of product of
PFAD supply to VWFII; such batch
even dioxin level at would have
≤0.6ng/kg can be to be
accepted internally and verified for
PFAD can be positive Dioxin
release by VWFII for compliance
direct Production use. (i.e.
<0.75ng/kg)
N0te**:
lnternailly accepted
Dioxin level (0.6ng/kg)
is based on the
following assumptions :
- PFAD
Contributes 75% of
0.6ng/kg = 0.45ng/kg
Issue Date :
Page :

- CaO & Other
Contribute 0.1ng/kg
Dioxin into finished
product
CCP 1 PFAD Dioxin Dioxin’s Action limit = 0.5ng Dioxin in certificate of Every Plant Action : Call HACCP LOG/VWFII - PROD - 18 No verification is
Purchase & (supply of WHOPCDD/FTEQ/kg PFAD analysis of the corresponding Executive / (1) if ‘results’ meeting for course of – 005 for in fact needed
Receiving Non-positive corresponding batch Sales Exceed Rejection limit action and review monitoring & since the
(Continue) Released Dioxin’s Rejection limit = 0.75 ng batch Manager (0.75ng/kg the supplier status verification “Positive
PFAD) WHOPCDD/FTEQ/kg releated PFAD plan ReleaseExcercise”
Note: batch is to be PFAD become “Positive is conducted at
Dioxin Internal accepted downgraded as release” if dioxin level is Certificate of VWFII
compounds Dioxin level = 0.6 ng WHOPCDD/ “Non-feed use”. below Action limit. If analysis by 3rd
Inciude : FTEQ/kg, Such PFAD would not, taken either Action party lab
· Di0xin During emergency case (see be either (i) rejected (1) & (2)
· Dioxinlike Note** at Corrective Actioncoloumn & returned to the
PCBs supplier or (ii) resell
· Non- it to other buyer for
Dioxin like “'non- feed use”.
PCBS
Based on (2) if results fall
COA results between Action limit
Over the (0.5ng/kg) and
years (since Rejection limit
2012), only (0.75ng/kg), VWFII
Dioxin is has the options of
“critical taking either action
hence only
Dioxin is
targeted for
CCP
Issue Date :
Page :

- Such nonpositive release PFAD (2a) or (2b) or (2c) or
can only be approved for a combination.
production use based on the
certificate of analysis on Dioxin, Action (2a) Verification for
issued by an accredited laboratory, Dilution with pesitive Action (2a)
indicating that the Dioxin results of release PFAD, shculd the diluted
the related PFAD we have access to batch. should
batch meet the GMP standard other batches of be verified
/specification. positive released by either (i)
PFAD with Dioxin laboratory
- Only then, the related batch level ≤0.5ng/kg for Dioxin test of
is classified as “Positive Release dilution purpose. the blended
PFAD” The new diluted / PFAD or (ii)
blended batch must Dioxin
have a lower Dioxin verification
level, ideally on the finished
≤0.5ng/kg; or at products made
internally acceptable from such
Dioxin level, i.e. blended PFAD.
maximum 0.6ng/kg Targeted dioxin
The new diluted / compliance of
blended batch can be the finished
released (24 hours product should
after blending) for be < 0.75 ng/kg
production use lf and when the
based on dilution blending
formulation (see formula is
QMQ(SP)/017) with verified later
the preceding and proof to be
condition that the reliable the
dioxin level of the blelended does
source PFAD is not need to be
known. tested for
Dioxin again
Issue Date :
Page :

after blending.
Likewise, its
finished
product.
Action (2b) Verivication for

In cases of action (2b)
emergency; like Finished
shortage of PFAD in product of such
the market or batch can be
prolonged delay of verified for
PFAD supply to Dioxin
VWFII:even Dioxin compliace (i.e
level at ≤0.6ng/kg <0.75ng/kg)
can be accepted Responsible:
internally and such Producailon
PFAD can be positive Executive
released by VWFII for Sales
direct production use. Manager
Note** :
- PFAD
Contributes 75% of
0.6ng/kg =
0.45ng/kg
- CaO & Other
Contribute
0.1ng/kg Dioxin
into finished
product
Action (2c)
To be rejected &
Returned to the
Issue Date :
Page :

supplier or resell it to
other buyers for as
“downgraded PFAD
or for “non-feed use”
Issue Date :
Page :

CCP 1 PFAD Dioxin Dioxin’s Action limit = 0.5ng Dioxin in Certificate of Related & Plant Action : Call HACCP FPF(MP) / 008 No verification is
Purchase & (Wrongly WHOPCDD/FTEQ/kg PFAD analysis of the Affected Executive / (1) if results meeting for agreed & 009 for in fact needed
Receiving uploading of corresponding batch Sales Exceed Rejection limit course of action monitoring & since the
(End) incoming Dioxin’s batch Manager (0.75ng/kg the Hold the affected verivication “Positive
non-positive Rejection limit = 0.75 ng “Positive releated PFAD batch until the dioxin plan ReleaseExcercise”
release PFAD WHOPCDD/FTEQ/kg urelease” if batch is to be level is ascertained Certificate of is conducted at
into tank that dioxin level downgraded as PFAD become “Positive analysis by 3rd VWFII
contain Internal accepted meets the “Non-feed use”. release” if dioxin level is party lab
positive Dioxin level = 0.6 ng WHOPCDD/ GMP+standart Such PFAD would below Action limit. If not, FPF(HM)015
Released FTEQ/kg, be either (i) rejected taken either Action (1) & PFAD Batch
PFAD) & returned to the (2) positive
Note: During emergency case (see supplier or (ii) resell release
Dioxin Note** at Corrective Action it to other buyer for tracking
compounds coloumn “'non- feed use”.
Inciude :
· Dioxin (2) if results fall
· Dioxin-like between Action limit
PCBs (0.5ng/kg) and
· Non- Rejection limit
Dioxin like
PCBS
Based on
COA results
Over the
years (since
2012), only
Dioxin is
“critical
hence only
Dioxin is
targeted for
CCP
Issue Date :
Page :

(0.75ng/kg), VWFII has
the options of taking
either action (2a) or
(2b) or (2c) or a
combination.
Action (2a)
Dilution with pesitive
release PFAD, shculd
we have access to
Verification for
other batches of
Action (2a)
positive released PFAD
the diluted
with Dioxin level
batch. should
≤0.5ng/kg for dilution
be verified
purpose.
by either (i)
The new diluted /
laboratory
blended batch must
Dioxin test of
have a lower Dioxin
the blended
level, ideally
PFAD or (ii)
≤0.5ng/kg; or at
Dioxin
internally acceptable
verification
Dioxin level, i.e.
on the finished
maximum 0.6ng/kg
products made
The new diluted /
from such
blended batch can be
blended PFAD.
released (24 hours
Targeted dioxin
after blending) for
compliance of
production use
the finished
based on dilution
product should
formulation (see
be < 0.75 ng/kg
QMQ(SP)/017) with
lf and when the
the preceding
blending
condition that the
formula is
verified later
and proof to be
reliable the
blelended does
not need to be
tested for
Dioxin again
Issue Date :
Page :

dioxin level of the after blending.
source PFAD is known. Likewise, its
Action (2b) finished
In cases of emergency; product.
like shortage of PFAD Verivication for
in the market or action (2b)
prolonged delay of Finished
PFAD supply to VWFII : product of such
even Dioxin level at batch can be
≤0.6ng/kg can be verified for
accepted internally Dioxin
and such PFAD can be compliace (i.e
positive released by <0.75ng/kg)
VWFII for direct
production use.
Note** :
- PFAD
Contributes 75% of
0.6ng/kg =
0.45ng/kg
- CaO & Other
Contribute 0.1ng/kg
Dioxin into finished
product
Action (2c)
To be rejected &
Returned to the
supplier or resell it to
other buyers for as
“downgraded PFAD or
for “non-feed use”

Responsible :
Production Executive /
Sales Maneger
Issue Date :
Page :

POA 1 Heavy metal Pb = 10mg/kg(ppm) Heavy Supplier’s At least Plant - Hold Entire CaO Lot In Call HACCP meeting for LOG/VWFII - PROD - 18 Lab test by 3rd
CaO as Lead (Pb) metal as Pb Certificate once a year Executive / Storage Tank. Draw CaO course of action an review – 005 for monitoring & party lab, at
Purchase & (Chemical) Of Analysis (because Sales Samples From Tank And supplier status verivication plan least once a
Receiving And / Or past result Manager Run Relevant Tests. year
Lab Test By showed - Test Megalac Stock In
VWFII low Warehouse For Heavy
incidence) Metal Through Random
Samples.
- Trance Test Result Of
Megalac To CaO
- If Megalac’s Heavy
Metal/ Dioxin Levels
Meet Standard, No
Recall/ Disposal of end
Products, Despite CaO
Heavy Metal/ Dioxin Out
Of Specs
- Return Contaminate CaO
(Whole Storage/
Blending Tanks) To
Supplier And Seek
Compensation
PLANNING & REALIZATION FEED PRODUCT

Keparahan Bahaya Kemungkinan Kejadian Apakah Potensi
Tingkat (Severity of Hazard) (Probability of Occurance)
Tahapan Proses Penerimaan di Bahaya
Occasionaly
No
Commonly
Signifikan
Very High
Un-Likely
Probable
(Process Step) Kategori Produk Akhir
(Is The Potential
High
(7.4.2)
Med
Bahaya Bahaya Potensial Sumber Bahaya
Low
(Hazard (Potensial Hazard) (Source of hazard) Hazard
Category) Significant)
1 2 3 4 1 2 3 4
1 PFAD Storagek (TK-F01 & TK- Biological - Insect rodent and pest Environment v v Not significant
F02) droppings
- Contamination through
external sources via opening
of Storage tank and loading
pipe at Pump house
Chemical - Dioxin compounds Previous Process v v Not significant

- Contamination Through wrong
transfer Of non- positive

Physical - Foreign materials such as dust & dirt. Environment v v Not significant
external sources via opening of storage
tank andPFAD
release loading
For pipe at Pump house
production
and during handling
2 Blending (112B01 & 112B02) Biological None. Not possible source of

Chemical introduction
None. Not possible source of
introduction
Physical None. Not possible source of

introduction
3 Mixing (101P01) Biological None. Not possible source of
introduction
3 Mixing (101P01)
Chemical None. Not possible source of

introduction
Physical Potential metal Moving Metal Parts v v Not significant
(Impeller)
5 CaO Storage (111B01A & Biological Insect and pest droppings Environment v v Not significant
111B01B)

introduction
Physical Contamination of foreign Suppliers v v Not significant
materials such as dust and dirt
4 BHT storage Biological Insects and pest droppings Environment v v Not significant
due to unhygienic of storage
area

introduction
Physical Dirt and dust due to Environment v v Not significant
unhygienic storage area
5 BHT addition to Biological None. Not possible source of

PFAD introduction
5 BHT addition to
PFAD
Chemical BHT toxicity due to over Failure of Weighing scale v v Significant
dosage via faulty weighing
scale
Physical Foreign materials such as dust Environment v v Not significant

& dirt.
opened cover during addition
6 Calcium Soap reactor top Biological None. Not possible source of

conveyor introduction
Chemical Food Grade Grease apply on Chemical use of v v Not significant

the bearings of the shaft that Equipment Part
move the conveyor
Physical Metal residue from wear & Equipment v v Significant

tear of metal parts in
manufacturing process
7 Re-work station into top Biological None. Not possible source of

introduction
7 Re-work station into top
conveyor
Physical Contamination of foreign v v Not significant

material like pieces of recycle
bags and dirt during handling
(feeding in the product for
reworking)
8 Calcium Soap reactor Biological None. Not possible source of

– Middle conveyor introduction
Chemical Food Grade Grease apply on Chemical use of v v Not significant
the bearings of the shaft that Equipment Part
move the conveyor
Physical Metal residue from wear & Equipment v v Significant

9 Calcium Soap Cooling conveyor Biological None. Not possible source of

introduction
Chemical Food Grade Grease apply on v v Not significant
the bearings of the shaft that
move the conveyor
Physical Metal residue from wear & v v Significant
10 Air Cooler Biological Flying insect, spiders etc v v Not significant

introduction
Physical Foreign materials such as dust v v Not significant
&dirt
11 Rework station into screw Biological None. Not possible source of

introduction
11 Rework station into screw
conveyor
Physical Contamination of foreign v v Not significant

material like pieces of recycle
bags and dirt during handling
(feeding in the product for
reworking)
12 Intermediate silo Biological None. Not possible source of

introduction
introduction
introduction
13 Calcium Soap Crushing Biological None. Not possible source of
system introduction
introduction
Physical Metal residue from wear & v v Not significant
tear of meta parts in
14 Cooling Using Swivel Cooler Biological Flying insect, spider etc v v Not significant
Chemical Hydraulic oil from hydraulic v v Not significant
unit
Lubricant for motor/gear oil of v v Not significant

rotating distributor unit
Physical Foreign materials such as dust v v Not significant

& dirt
15 Magnet Trap after Screw Biological None. Not possible source of

Conveyor 104H07 introduction
for 25Kg
Bagging line Chemical None. Not possible source of
introduction
Location Physical Metal residue accumulated v v Significant
Before hopper from manufacturing process
of 25kg filling
line
16 Calcium Soap 25kg Biological None. Not possible source of

packaging Plant introduction
introduction
introduction
17 Metal Detection Biological None. Not possible source of
at 25kg packing introduction
line

introduction
17 Metal Detection
at 25kg packing
line
Physical Metal residue accumulated v v Significant

from manufacturing process
19 Magnet Trap after Screw Biological None. Not possible source of

Conveyor 104H07 introduction
for 650Kg
Bagging line Chemical None. Not possible source of
introduction
Location Physical Metal residue accumulated v v significant
Before hopper from manufacturing process
of 650kg filling
line
20 Metal Biological None. Not possible source of

detection at introduction
650 kg paper bag packing
line

introduction
detection at
650 kg paper bag packing
line
Physical Metal residue accumulated v v Significant

from manufacturing process
21 Calcium Soap 650 kg Biological None. Not possible source of

Jumbo bag packing line introduction
introduction
Physical None. Not possible source of Non significant
introduction
nformasi : (K = Kimia, F = Fisika, B = Biologi)

Keterangan:
Persyaratan ISO 22000:2005
1. Klausul 7.4 : Analisa Bahaya
entifikasi Bahaya dan Penentuan Tingkat Yang Dapat Diterima
Klausul 7.4.3 : Assesmen / Penilaian Bahaya
7.4.4 : Seleksi dan Assesmen Tindakan Pengendalian
dalikan dengan PRP maka tidak perlu dilanjutkan ke decision tree

n tree refer to Codex CAC/RCP 1-1969, Rev.4-2003
MANAGEMENT SYSTEM Rev. :
Issue Date :
Effective. Date :
EED PRODUCT
Page :
Pemilihan Tindakan Pengendalian Penentuan CCP

ahaya (Hazard Analysis) (7.4.3) Identify Control Measures (7.4.4) (CCP Determination)
Decision Tree
PRP / oPRP / CCP

(Based on Codex)
Referensi Undang-undang, Referensi Undang-undang,
Standar Industri, dan/atau Control Measures Standar Industri, dan/atau
Alasan kontrak perjanjian *Jika bahaya bisa dikendalikan Referensi Dokumen kontrak perjanjian
(Justification) (Legislation, Industry dengan PRP maka tidak perlu (Document Reference) (Legislation, Industry
Standard, and/or Contract dilanjutkan ke decision tree Standard, and/or Contract
Terms Reference) Q1 Q1a Q2 Q3 Q4 Terms Reference)
Pb & s = low, because : Pest has Y Y PRP

no access to PFAD through
openings.
Manhole of storage
tanks are closed and loading
pipe are covered when not in
use.
Pipeline is a close loop system
and, there is a strainer / filter
prior to tanks, and also there is a pest
control program in place
Pb & s = low, because : have a compliant Y Y PRP

CoA from QC Dept. and Third party's
Lab.
Pb & s = low, because : General Control Y

- Manhole openings of storage - Periodic checking of
tanks are closed. strainer at PFAD
- Pipeline of PFAD transferring receiving and record
out from storage tanks is a observation – at least
close loop system once in month
PB & S = medium, because : Y N Y oPRP
Downstream Magnet/metal detection ;
Magnet strenght checked anually
Pb & S = low, because CaO is Y Y PRP

caustic chemical that no pests
like.
Manhole openings are closed
and loading pipe are covered
when not in use.
Pb & S = low, because silo is Y Y PRP

part of lose loop system.
Loading pipe are covered when
not in use
Pb & S = low, because BHT is Y Y PRP

protected by bags.
Opened bags are stored in
container with covered.
Cleaning program of storage
place is in place.
Pb & S = low, because BHT is Y Y PRP

protected by bags.
Opened bags are stored in
container with covered.
Cleaning program of storage
place is in place.
Pb = low, because BHT is not Genaral Control Y N Y oPRP
added directly from its bag but - Periodic verification
weighted by calibrated of weighing scale
weighing scale before dosing
into blending tank
S = medium, dosage is only
0.15% in PFAD Megalac /
CaSPFA / CaSPFA (84% PFAD) is
served as supplementary feed,
i.e. feeding rate is only 500-
700g / day / cow and not as a
main staple. Therefore severity
and risk of “over dosage
poisoning” is not high
Y Y PRP
High temperature area where

exothermic reaction happens
(>100 oC)
Pb = Low because bearings are Y Y PRP
located outside of the Reactor
chamber. Neither does the
grease sips through the metal
wall nor transferred by the
shaft to the product.
S = Low because grease used is
food grade
Pb = Medium because wear Y N Y oPRP

and tear bound to happen with
time.
especially this is an area
whereby chemical reaction
between acid + caustic base
actively taking place
S = Medium, metal piece when
ingested by cattle can hurts its
internal organs.
Pb = Low, very little product of Y N Y oPRP
this sort for rework at this
point.
Foreign material will likely
trapped by filter at sieve at
later stage

food grade
Pb = Medium because wear General Control Y N Y oPRP

and tear bound to happen with - Magnetic strainer at
time. Bucket Elevator
after sieve & milling
machine
- Built-in process of
screening end
product by metal
detector before
palletizing
Standaerd Operating procedure

on Pull
test and Drop Test to
ensure magnetic
strainer/ grid is still
functioning Frequency
= weekly checking

food grade
Pb = Medium because wear General Control Y N Y oPRP
and tear bound to happen with - Magnetic strainer at
time. Bucket Elevator
machine
- Built-in process of
screening end
product by metal
detector before
palletizing
Working instruction 16
in FPW(MP)012 on Pull
test and Drop Test to
ensure magnetic
strainer/ grid is still
functioning Frequency
= monthly checking
Pb & S = Low, because air Check overall condition

intake through air filter of the air filter daily &
clean the air filter
weekly
Pb & S = Low, because Air Check overall condition

intake through air filter Low of the air filter daily &
clean the air filter every
2 weeks
Pb = Low, very little product of Y Y PRP
this sort for rework at this
point.
Foreign material will likely
trapped by filter at sieve at
later stage
Pb = low, machine is designed General Control Y N Y oPRP

to be heavy duty to withstand - Magnetic strainer #1
wear & tear during milling. at Bucket Elevator #3
machine
Working instruction 16
in FPW (MP) 012 on Pull
Test and Drop Test to
ensure magnetic
strainer / grid is still
functioning. Frequency
= monthly checking
Pb = Medium because, Installed filter at the Y N Y oPRP

although the unit is located opening of the air inlet
indoor, there are chances of Clean the filter weekly
insects enter the system via the
opening of the air inlet on both
side of the unit.
S = Low because we have Pest
control program and
housekeeping in place.
Pb & S = Low because the Check for any oil leak Y Y PRP
Hydraulic unit is located and working condition
outside of the unit and Food hydraulic unit and
grade Hydraulic Oil is used rotating distributor unit
Pb & S = Low because the
motor is located outside of the
unit and food grade lubricant is
used. Also, the shaft leading to
the cooling bin is cased.
Pb = Medium because, Installed filter at the Y Y PRP

although the unit is located opening of the air inlet
indoor, there are chances of Clean the filter weekly
insects enter the system via the
opening of the air inlet on both
side of the unit.
S = Low because we have Pest

control program and
housekeeping in place.
PB = high because of likeness of Enhanced magnet Y N N Y N oPRP

accumulation of metal residue monitoring and
from wear and tear of metal cleaning program
parts of the entire
S = medium because metal
pieces or accumulated dust can
be hurtful to Cows’ digestion
and health
PB & S = high because of Specific Control Y N N Y N CCP
likeliness of accumulation of - Screening of end
metal residue from wear and product using metal
tear of metal parts of the entire detector before
manufacturing process palletizing.
- Verification of
Metal Detector’s
ability to detect
metal and
sensitivity before
every production
- Periodic calibration
of metal detector
PB = high because of likeliness Enhanced magnet Y N N Y N oPRP

of accumulation of metal monitoring and
residue from wear and tear of cleaning program
metal parts of the entire
S = medium because
metal pieces or
accumulated dust can be
hurtful to Cows’ digestion
and health
PB = high because of likeliness Specific Control Y N N Y N CCP
of accumulation of metal - Screening of end
residue from wear and tear of product using metal
metal parts of the entire detector before
manufacturing process Filling/ bagging.
- Verification of
Metal Detector’s
ability to detect
metal and
sensitivity before
every production
- Periodic calibration
of metal detector
GOOD MANUFACTURING PRACTICE +B2 Document No.
CALCIUM SOAP DEPARTEMENT Rev.
Issue Date
PRODUCTION PROCESS CALCIUM SOAP Effective. Date
Page

hazard) (corrective action)
PFAD Storage tank in Dioxin due to Dioxin’s Dioxin in finished Certificate of Related & affected Plant executive / Case1 : When non-positive Certificate of Verivication
PH3 wrong transfer of Rejection limit = 0.75 ng WHO- product analysis on dioxin batch of finished Sales manager release PFAD is yet to be analysis by 3rd on case 1
Non-positive PCDD/FTEQ/kg product produced produced as finished party lab Verivication
release PFAD during first and product Discharge the non- on the finished
for production second 20 minutes positive release PFAD product
of production batch back to the closest produced
20minutes storage tank that can be during the first
production is isolated from thepositive two batch of
equivalent to 1.7MT release PFAD; if the 20 minute of
of finished affected volume permits production.
product produced E.g. Discharge non-positive If dioxin result
release PFAD from PFAD <0.75ng/kg,
Day Tank to PH3 PFAD fnished
Storage Tank and lock out product is
the acceptable
wrong PFAD from if Dioxin result
contacting the positive >0.75ng/kg,
release PFAD. reject and
Flush out the wrong PFAD dispose the
in pipeline using Pigging affected
misile. These flushout finished
PFAD can be considered product or
as part of nonpositive rework
release PFAD Reworked
product need
to be tested
again for
Dioxin, so to
verify rework rate and act as
a basis for
releasing the
product for
sales.
Issue Date
Page

Case2 : When non- positive

release PFAD has been
produced as finished
product
Repeat corrective action for
the balance PFAD that has
yet to be used for
production
Hold the finished product
thjat is produced using the
non-positive released
PFAD.
Take sample and send for
dioxin test.
If dioxi result is <0.75ng/kg,
finshed product is
acceptable
if Dioxin result >0.75ng/kg,
reject and dispose the
affected finished product or
rework the product at a
certain inclusion rate
Reworked product
need to be tested
again for Dioxin, so
to verify rework rate
and act as a basis
A for releasing the
product fur sales.
Issue Date
Page

POA 2 Over dosage ±0.15% of Weight (kg) Using Once for 1 batch Plant Hold Blending Process. LOG/VWFII - PROD - 18 Monthly stock
BHT of BHT specification PFAD standart PFAD blend operator Calibrate Weighing Scale. – 001 reference
addition to (Chemical) addition weight before for monitoring
PFAD production records
LOG/VWFII - PROD - 18
– 002
for verification
BHT stock
reference
Issue Date
Page

CCP1 Metal 1. 3.5 mm-Fe Pass Using Using test Once a shift foreman/ Repeat till metal detector For daily record on - Yearly
Metal Detection (25kg residues 2. 4.5 mm- Non Fe test piece or operator sensitivity is confirmed and calibration calibration
bagging line) (physical) 3. 5.0 mm- SS sensitivity before restored. LOG/VWFII - PROD - 18 - Verify on
piece start up production lf repeatedly fail, halt – 003, the
test production / packing. Hold for FRPD (form record monitoring
products until problem is process detection) on records
solved. metal once a shift.
Re-scan previous batches detection Responsible :
when problem is solved. LOG/VWFII - PROD - 18 Foreman production
lf metal detection is found – 008. Head of department.
in product during re-scan,
the affected product is to
be screened through
portable magnet at rework
station (at screw conveyor)
Issue Date
Page

Alternative Measure LOG/VWFII - PROD - 18

/ Approach: – 003 Nonconforming
Depends on practical / product
commercial reason, management,
Alternative Measure can (Management
take place instead of the of goods when
above. metal
Execution of Alternative detection
Measure can happen based fails),
on following circumstances, (Reworking of
1) When Metal Detector goods
is suspected to be not detected with
working in perfect / Metal) &
ideal condition magnetic test)
2) Rectification is in LOG/VWFII - PROD - 18
progress or if – 007
rectification take more for Non
than 1 working day, as Conforming
per supplier’s input, goods record
e.g. non available of LOG/VWFII - PROD - 18
spare parts / repair – 007
service. & action LOG/VWFII -
Decision to execute PROD - 18 – 007
Alternative Measure relies for magnet
on HACCP Team decision, cleaning LOG/VWFII -
with supports. PROD - 18 – 004.
Decision must be
supported
by head of department.
Issue Date
Page

3) Assessment of past
monitoring results
showing no alarming
trend on presence of
metal pieces / metal
dust on Magnet
4) Records shown metal
detector has been
passing sensitivity
tests
Altemative Measure which
is The Enhanced and
Cleaning Program:
- Ensure magnet #1
passes verivication of
Magnetic strength test
before start of
Alternative Measures
- Keep production going
but have to check
Magnet # 1 located
after Screw Conveyor
(25kg bagging
line) every 2
hours as production
commence. If found
metal dust / metal
pieces, record findings
and clean magnet by
blowing it using
pressurized air.
- Records findings and
remedy action in
LOG/VWFII - PROD - 18 –
003
- Cleanliness of
Magnetic plate at
every bucket elevator &
before swivel cooler tank
are also
being monitored once a
2 week.
Issue Date
Page

So to enhance magnetic
removal of any metal
dust / metal pieces
Continue verifying magnetic
strength of Magnet as
on SOP in SOP/VWFII-
PROD-18-010 for
every 2 weeks.
Alternative Measure to be
halted when
a) VWFII found spare unit
of Metal Detector
b) Metal detector
problem is rectified.
Issue Date
Page

CCP2 Metal 1. 3.5 mm-Fe Pass Using Using test Once a shift foreman/ Repeat till metal detector For daily record on - Yearly
Metal Detection (650 kg residues 2. 4.5 mm- Non Fe test piece or operator sensitivity is confirmed and calibration calibration
bagging line) (Physical) 3. 5.0 mm- SS sensitivity before restored. LOG/VWFII - PROD - 18 - Verify on
piece start up production lf repeatedly fail, halt – 003, the
test production / packing. Hold for FRPD (form record monitoring
products until problem is process detection) on records
solved. metal once a shift.
Re-scan previous batches detection Responsible :
when problem is solved. LOG/VWFII - PROD - 18 Foreman production
lf metal detection is found – 008. Head of department.
in product during re-scan,
the affected product is to
be screened through
portable magnet at rework
station (at screw conveyor)
Issue Date
Page

Alternative Measure LOG/VWFII - PROD - 18

/ Approach: – 003 Nonconforming
Depends on practical / product
commercial reason, management,
Alternative Measure can (Management
take place instead of the of goods when
above. metal
Execution of Alternative detection
Measure can happen based fails),
on following circumstances, (Reworking of
1) When Metal Detector goods
is suspected to be not detected with
working in perfect / Metal) &
ideal condition magnetic test)
2) Rectification is in LOG/VWFII - PROD - 18
progress or if – 007
rectification take more for Non
than 1 working day, as Conforming
per supplier’s input, goods record
e.g. non available of LOG/VWFII - PROD - 18
spare parts / repair – 007
service. & action LOG/VWFII -
Decision to execute PROD - 18 – 007
Alternative Measure relies for magnet
on HACCP Team decision, cleaning LOG/VWFII -
with supports. PROD - 18 – 004.
Decision must be
supported
by head of department.
Issue Date
Page

3) Assessment of past
monitoring results
showing no alarming
trend on presence of
metal pieces / metal
dust on Magnet
4) Records shown metal
detector has been
passing sensitivity
tests
Altemative Measure which
is The Enhanced and
Cleaning Program:
- Ensure magnet #1
passes verivication of
Magnetic strength test
before start of
Alternative Measures
- Keep production going
but have to check
Magnet # 1 located
after Screw Conveyor
(25kg bagging
line) every 2
hours as production
commence. If found
metal dust / metal
pieces, record findings
and clean magnet by
blowing it using
pressurized air.
- Records findings and
remedy action in
LOG/VWFII - PROD - 18 –
003
- Cleanliness of
Magnetic plate at
every bucket elevator &
before swivel cooler tank
are also
being monitored once a
2 week.
Issue Date
Page

So to enhance magnetic
removal of any metal
dust / metal pieces
Continue verifying magnetic
strength of Magnet as
on SOP in SOP/VWFII-
PROD-18-010 for
every 2 weeks.
Alternative Measure to be
halted when
a) VWFII found spare unit
of Metal Detector
b) Metal detector
problem is rectified.
REWORKING OF CALCIUM SOAP

Tingkat Keparahan Bahaya Kemungkinan Kejadian

Tahapan Proses Penerimaan di (Severity of Hazard) (Probability of Occurance) Apakah Potensi
No Bahaya Signifikan
(Process Step) Kategori Produk Akhir
Occasional
Commonly
Very High
Un-Likely
(Is The Potential
Probable
Bahaya Bahaya Potensial Sumber Bahaya (7.4.2)
Hazard Significant)
High
Med
Low
(Hazard (Potensial Hazard) (Source of hazard)
y
Category)
1 2 3 4 1 2 3 4
1 Calcium Soap Biological None. Not possible source
Reject & Storge of introduction
For Rework
Product Type 1
Chemical None. Not possible source

of introduction
Physical None. Not possible source

of introduction
2 Calcium Soap Biological - Pests like rat, insect v v Not significant

Reject & Storge
For Rework
Product Type 2
Mold due to damped v v Not significant

intermediate product
Chemical Mineral oil and lubricants v v Not significant
on equipment part
Physical Foreign material like dust v v Not significant

from environment
MANAGEMENT SYSTEM Rev. :
Issue Date :
Effective. Date :
UM SOAP
Page :
Pemilihan Tindakan Pengendalian Penentuan CCP

a (Hazard Analysis) (7.4.3) Identify Control Measures (7.4.4) (CCP Determination)
Decision Tree
Referensi Undang-undang, (Based on Codex) Referensi Undang-undang,
OPRP / CCP
Standar Industri, dan/atau Control Measures Standar Industri, dan/atau
Alasan kontrak perjanjian *Jika bahaya bisa dikendalikan Referensi Dokumen kontrak perjanjian
(Justification) (Legislation, Industry dengan PRP maka tidak perlu (Document Reference) (Legislation, Industry
Standard, and/or Contract dilanjutkan ke decision tree Standard, and/or Contract
Terms Reference) Q1 Q2 Q3 Q4 Terms Reference)
QC Rejected Finished product

are still securely packed in
Calcium Soap bags

Calcium Soap bags
Calcium Soap bags
Pest Control
Program is in place
- Although product have to be
with storage bag mouth’s
opened, they are semi
covered
- Note: Rework Product is
reintroduced
inito the process
at the point where
temperature > 100C
Product is kept at ventilated

area and with storage bag’s
mouth opened / loosely
covered, in order to prevent
anaerobe condition that
encourage mold growth
- No mineral oils / lubricants is
used in Reactor, because
Calcium Soap itself is oil
product which serves as
lubricant of moving parts.
- So, Rework product should
be safe from such
contamination
- Maintain good hygiene

housekeeping at storage area
Document No. :
VOLAC WILMAR FEED INGREDIENTS INDONESIA Rev. :
Issue Date :
Effective. Date :
HACCP PLAN - HAZARD ASSESSMENT MATRIX
Page :
Table 1. Risk Ranking Scheme based upon severity of risk and probability of hazard as decsribed by Bovee et al (1997)
(Bovee, E.H.G.; de Kruijf, N.; Jetten, J. & Barendsz, A.W. HACCP Approach to Ensure the Safety and Quality of Food Packaging. Food Additives and Contaminants.17(6-7), 721-735. 1997)
Severity Likelihood
Low Terganggu kesehatan/inconvinience Unlikely (jarang) > 12 month

(1) (1)
Medium sakit/rawat jalan Occasionally (kadang-kadang) once per 12 months

(2) (2)
High Probable (sering)

(3) sakit kronis/rawat inap/operasi (3) once per 6 months
Very high meninggal Common (selalu) once per month or every

(4) (4) delivery/shipment
Likelihood
Unlikely (1) Occasionally (2) Probable (3) Common (4)
non-significant
(controlled by PRPs)
Low (1) 2 3 4 5
significant
Medium (2) 3 4 5 (controlled by OPRPs 6
Severity or CCPs)
High (3) 4 5 6 7
Very High (4) 5 6 7 8
Keputusan Tidak signifikan jika jumlah probability dan severity < 6

Keputusan Signifikan jika jumlah probability dan severity ≥ 6
Document No. :
VOLAC WILMAR FEED INGREDIENTS INDONESIA Rev. :
Issue Date :
Effective. Date :
HACCP PLAN - DECISION TREE
Page :
2014-01-29 - HACCP: Identification of CCP, CP, PRP, oPRP in the standards IFS, BRC, ISO 22000 – practical examples

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HACCP PLANT TABLE FEED SAFETY MANAGEMENT SYSTEM

Identifikasi Bahaya Analisa Bahaya (Hazard Analysis) (7.4.3)

Keparahan Bahaya Kemungkinan Kejadian Apakah Potensi

- Dioxin compounds v v Not Significant Pb = Low because (a)

S= Medium because all these

Biological Mold and microbiology v v Significant Pb = probable, performance

Biological Insect and mold v v Not significant Pb & S = low, because

Informasi : (K = Kimia, F = Fisika, B = Biologi)

PRP/ OPRP / CCP

General control Y N Y CCP

General Control Y N Y oPRP

Monitor quality from CoA from Y PRP

By using 10 mikron filter bag Y N Y

Install UV filter before process Y N Y

Visual check procedure and CoA Y PRP

Visual check procedure. Y PRP

Visual check procedure and Y PRP

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Action (2b) Verification

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Action (2b) Verivication for

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

Bahaya Prosedur Pengawasan (7.6.4)

for “non-feed use”

Bahaya Prosedur Pengawasan (7.6.4)

PLANNING & REALIZATION FEED PRODUCT

Identifikasi Bahaya Analisa Bahaya (Hazard Analysis) (7.4.3)

Chemical - Dioxin compounds Previous Process v v Not significant

transfer Of non- positive

2 Blending (112B01 & 112B02) Biological None. Not possible source of

Physical None. Not possible source of

Chemical None. Not possible source of

Chemical None. Not possible source of

Chemical None. Not possible source of

5 BHT addition to Biological None. Not possible source of

Physical Foreign materials such as dust Environment v v Not significant

6 Calcium Soap reactor top Biological None. Not possible source of

Chemical Food Grade Grease apply on Chemical use of v v Not significant

Physical Metal residue from wear & Equipment v v Significant

7 Re-work station into top Biological None. Not possible source of

Physical Contamination of foreign v v Not significant

8 Calcium Soap reactor Biological None. Not possible source of

Physical Metal residue from wear & Equipment v v Significant

9 Calcium Soap Cooling conveyor Biological None. Not possible source of

10 Air Cooler Biological Flying insect, spiders etc v v Not significant

Chemical None. Not possible source of

11 Rework station into screw Biological None. Not possible source of

Physical Contamination of foreign v v Not significant

12 Intermediate silo Biological None. Not possible source of

Lubricant for motor/gear oil of v v Not significant

Physical Foreign materials such as dust v v Not significant

15 Magnet Trap after Screw Biological None. Not possible source of

16 Calcium Soap 25kg Biological None. Not possible source of

Chemical None. Not possible source of

Physical Metal residue accumulated v v Significant

19 Magnet Trap after Screw Biological None. Not possible source of