MODEL OF HAZARD ANALYSIS AND CRITICAL CONTROL POINT PLAN

OF MEAT PIE IN A MEDIUM-SIZED BAKERY

MUHAMMAD AIDIL WAFI BIN ROSLI

MUHAMMAD AJWAD BIN MOHD SALLEH
MUTHIAH NURI RAHMANI
NOOR INTAN SHAMIMI BINTI ABDUL HAMID
NOR HAIZAADIELA BINTI ABDUL RAHMAN

A project paper submitted in partial fulfilment of the requirements

for the subject Food Microbiology SMBT3333-02 Semester 1
Session 2020/2021

Department of Biosciences
Faculty of Science
Universiti Teknologi Malaysia

DECEMBER 2020
 ABSTRACT

The purpose of this project is to plan a Hazard Analysis and Critical Control
Point (HACCP) model for meat pie for a medium-sized bakery. The 12 steps of
HACCP planning have been done included 7 HACCP principles in order to determine
the critical control point of the meat pie production and process to ensure the safety
and cleanliness of the meat pie production. The model provided with HACCP team,
product description, product’s intended used identification, products flow diagram
process, on-site products flow diagram process, hazard analysis comprised of
biological, chemical and physical hazards, critical control point identification,
monitoring procedures, corrective action, verification process and record-keeping
procedure.

i
 ABSTRAK

Tujuan projek ini adalah untuk merancang model Analisis Bahaya dan Titik
Kawalan Kritikal (HACCP) untuk pai daging bagi kedai bakeri bersaiz sederhana.
Terdapat 12 langkah perencanaan HACCP telah dilakukan merangkumi 7 prinsip
HACCP untuk menentukan titik kawalan kritis pengeluaran dan proses pai daging
demi memastikan keselamatan dan kebersihan pengeluaran pai daging. Model ini
disediakan dengan pasukan HACCP, keterangan produk, pengenalpastian kegunaan
produk, proses rajah aliran produk, proses rajah aliran produk di lokasi, analisis bahaya
terdiri daripada bahaya biologi, kimia dan fizikal, pengenalpastian titik kawalan
kritikal, prosedur pemantauan, tindakan pembetulan, proses pengesahan dan prosedur
penyimpanan rekod.

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 TABLE OF CONTENTS

TITLE PAGE

ABSTRACT i
ABSTRAK ii
TABLE OF CONTENTS iii

SECTION 1 INTRODUCTION 1
1.1 HACCP 1
1.2 Origin of HACCP 1
1.3 HACCP Concept 2
1.4 Benefits of HACCP 3

SECTION 2 HACCP METHODOLOGY 4

2.1 Introduction 4
2.2 Establishment of HACCP Team 4
2.3 Product Description 4
2.4 Identification of Product’s Intended Used 5
2.5 Process Flow Diagram and Plant Schematic 5
2.6 On-Site Process Flow Diagram and Plant Schematic 5
2.7 Principle 1: Hazard Analysis 5
2.8 Principle 2: Establishment of Critical Control Point 10
2.9 Principle 3: Establishment of Critical Limit 11
2.10 Principle 4: Establishment of Monitoring Procedure 12
2.11 Principle 5: Establishment of Corrective Action 12
2.12 Principle 6: Establishment of Verification Process 12
2.13 Principle 7: Establishment of Record-Keeping
Procedure 13

iii
SECTION 3 TERMS OF REFERENCE 14
3.1 Operation Flow 15
3.2 Type of Hazards 15
3.3 Product Description 15
3.4 Intended Use of the Products 15
3.5 Consumers including ‘At Risk’ Groups 16
3.6 Packaging, Storage and Distribution 16
3.7 Processing and Safety Information 16

SECTION 4 MODEL OF HACCP PLAN OF MEAT PIE 17

4.1 Establishment of HACCP Team 17
4.2 Product Description 18
4.3 Identification of the Product’s Intended Use 19
4.4 Meat Pie Process Flow Diagram 20
4.5 On-Site Confirmation of Flow Diagram: Meat Pie 21
4.6 Principle 1: Hazard Analysis 22
4.7 Principle 2: Establishment of Critical Control Point 31
4.7.1 Critical Control Point: Ingredient 31
4.7.2 Critical Control Point: Process Step 33
4.8 Principle 3: Establishment of Critical Limit 36
4.9 Principle 4: Establishment of Monitoring Procedure 38
4.10 Principle 5: Establishment of Corrective Action 42
4.11 Principle 6: Establishment of Verification Process 47
4.12 Principle 7: Establishment of Record-Keeping
Procedure 52
4.13 HACCP Plan: Meat Pie 58

SECTION 5 MEDIUM-SIZED BAKERY FLOOR PLAN 61

5.1 Floor Plan 61
5.2 Floor Plan References 62

REFERENCES v

iv
 SECTION 1

INTRODUCTION

1.1 HACCP

Hazard Analysis and Critical Control Point (HACCP) is a system that have
been applied to regulate safety of a process by identifying the critical point during the
production of a product in the industry to minimize or reduce any possibility that might
happened and causing problems. HACCP is considered as one of risk management
model that have been expanded to ensure the safety of the production by applying its
concept that comprised of 12 steps. In food industry, it widely uses to determine the
hazards from three categories which are biological, chemical and physical hazards to
avoid any foodborne outbreak or even the food poisoning etc. HACCP is a type of
measurement that ensure the quality of the food from its raw material until the finishing
product.

1.2 Origin of HACCP

According to Forsythe and Hayes (1998), the HACCP was originated from the
ideas to be applied for space exploration preparation. They stated that Pillsbury
Company, NASA and the US Army laboratories were collaborated to proposed
HACCP to ensure the food is safe for the astronauts and the development was based
on the Failure, Mode and Effect Analysis (FMEA) that been used in construction
designs by engineers. The HACCP was then introduced in the United States in 1971
at the Conference of Food Protection and been recommended for widely used (FDA,
1972; Bauman, 1974; Forsythe & Hayes, 1998). Eventually, the HACCP principle and
concept were being adopted in Codex Alimentarius Commission (1993) and the
National Advisory on Microbiological Criteria for Foods (NACMCF, 1992) globally
in food industry for safe food production.

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 1.3 HACCP Concept

The Figure 1.1 below is an HACCP Concept based on Codex Alimentarius

Commission (CAC) which listed with 12 steps comprised of 7 HACCP principles:

Figure 1.1 Steps in developing and implementing HACCP according to CAC.

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1.4 Benefits of HACCP

There are several benefits in applying HACCP plan system:

• Preventing the withdrawal of food product produced

• Preventing factory/shop closure.
• Improving product security.
• Factory repair and cleaning.
• Preventing loss buyers or customers or markets.
• Increasing customer trust.
• Preventing waste of costs or losses that may arise due to product security
issues.

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 SECTION 2

HACCP METHODOLOGY

2.1 Introduction

This HACCP methodology is to provide the details and reasoning including

term of reference for the execution of the model HACCP plan for meat pie production
by following the CAC guideline in HACCP and developing ideas from each members
of the group.

2.2 Establishment of HACCP Team

Establishment of HACCP team is important to plan the whole HACCP system

for a food production. Every member shall be an expert in their own study field
regardless any background involved to analyse each component of the system and the
material to develop an efficient HACCP system. The team shall be containing a
member from different disciplines of science such as microbiologist, technologist,
specialist and chemist to initiate the idea in taking a decision. The HACCP team could
also be assigned to a third party who are expert with the system.

2.3 Product Description

Product description is a component that will be focused on after the

establishment of HACCP team. This description includes the name of the product, the
composition or nutrient gain, its characteristics, processing and preserving method, its
primary packaging, storage condition, distribution method, its shelf life, the labelling
on the packaging and the instruction provided on the labelling for customers to aware
about the handling of the food. The HACCP team will analyse and evaluate the product
to be expanded and applied to the system to maintain its quality throughout the process
of food production.

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 2.4 Identification of Product’s Intended Used

HACCP team will analyse the food and study its influence to particular age
group as buyers for providing certain discipline of a process in HACCP system to
determine its safeness to be applied in HACCP system to that age group. This
consumption could be from directly consumer (e.g., freshly cooked product or cooled
product) or indirectly consumer (e.g., frozen product) and from either baby, kid,
adolescent, young adult, adult or geriatric buyers. They will make sure the HACCP
system could provide the safest process and balance their safeness for all age groups.

2.5 Process Flow Diagram and Plant Schematic

Process flow diagram and plant schematic is a process flow that recorded from
its raw material until its finishing product. From the diagram, the HACCP team will
manage to extract the detail of its production in early process and be applied to HACCP
system. The diagram and schematic were done to give a fundamental idea of the food
production overall process.

2.6 On-Site Process Flow Diagram and Plant Schematic

On-site process flow meaning the actual process flow happened during the
operation from its delivery of the raw material to its finishing product. This is a much
detail process flow where HACCP team could able to analyse each HACCP
profoundly and detect any defect from the process flow and suggesting the HACCP
guideline to be followed.

2.7 Principle 1: Hazard Analysis

Hazard analysis is an important part before continuing with the identification

of critical limit. After the completion of previous steps, HACCP team will analyse the
hazard present for each process. The hazard could be either biological, chemical or
physical followed by several categories to determine its severity. The purpose of this

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analysis is to recognize any hazards that might present since early process until bought
by customers. The types of hazard could be observed as:

Type of Hazards Details

Biological Bacteria, viruses, pathogen that may leads to foodborne

Hazard outbreak or food poisoning or food spoilage etc.

Chemical Natural toxins that secreted by the pathogen and chemical

Hazard contaminants that present in the food.

Physical Hazard Any foreign material that should not be eaten present in the food
e.g., hair inside food.

Table 2.1 Type of Hazards and their details.

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 According to Sudarmaji (2005), there are six hazard characteristics according
to NACMCF (1989):

Hazard Characteristics
Groups

Hazard A A hazard group that causes the designed product and intended used
for the risk particular age group (i.e., baby, old folks, sick people,
or low immune body) become unsterile.

Hazard B Product that contains sensitive material towards biological hazards.

Hazard C The process done did not follow effective operation for destroying
the hazardous pathogen.

Hazard D Re-contaminated product after processing and before packaging.

Hazard E Present of potential hazard on the handling during distribution or

consumption until it becomes hazardous to consume.

Hazard F Have no final heating process after the packaging or when cooked
at home.

Table 2.2 Hazard groups and their characteristics.

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 The severity of each ingredient’s component could be measured as suggested
by NACMCF (1989) (Sudarmaji, 2005):

Hazard Categories Details

Characteristics

0 0 No hazards (USDA, 1993)

(+) I If the food product has one characteristic

(between B-F)

(+ +) II If the food product has 2 characteristics

(between B-F)

(+ + +) III If the food product has 3 characteristics

(between B-F)

(+ + + +) IV If the food product has 4 characteristics

(between B-F)

(+ + + + +) V If the food product has 5 characteristics

(between B-F)

A+ VI If the food product has Hazard A or added

with another hazards (between B-F)

Table 2.3 Hazard categories and their characteristics.

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 Through the understanding of the types of hazard, hazard groups and the hazard
characteristics, the severity and frequency could be measure thoroughly and carefully
before proceeding with the identification of critical limit. The relationship between
severity and frequency could be observed as:

Level of Severity

L M H

Reasonably l Ll Ml Hl
likely to occur
(frequency) m Lm Mm Hm*

h Lh Mh* Hh*

Table 2.4 Relationship between level of severity and frequency of the severity to occur

* Considered as significant and hazardous and shall be confirmed as critical control

point.
Note: L=l = low, M = m = medium, H= h = high.

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 2.8 Principle 2: Establishment of Critical Control Point

Critical Control Point (CCP) has two aspect of establishment i.e., ingredient
CCP and process step CCP. Both will be carefully evaluating through their decision
tree of CCP:

Figure 2.1 Critical Control Point Decision Tree of Ingredients

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 Figure 2.2 Critical Control Point Decision Tree of Process Step

2.9 Principle 3: Establishment of Critical Limit

Critical limit (CL) is a minimum criterion that must be obeyed for every
process to prevent and ensure the safety of the process and ingredient. The limit is a
measurement for either the product should be acceptable or otherwise. This is
important moreover during monitoring procedure to control the quality for each and
every of the same product.

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 CL will be set up relating to the CCP component. If the component applied to
the CCP, it means, the CL must be studied and established. The CL could consist of
biological limit (e.g., microbe concentration), chemical limit (e.g., pH of the food),
physical limit (e.g., temperature or period).

2.10 Principle 4: Establishment of Monitoring Procedure

Monitoring procedure is a process that develop a schedule for testing and

analysis to handle CCP and CL to ensure its quality and its efficiency of the HACCP
system. The procedure consists of 4W and 1H question to be answered; What its
characteristics for CL and CCP to be signalled? How to determine or observed the
signal? Where the signal should be observed? Who is responsible to observe the
signal? And When (frequency) the signal should be observed? The signal stated above
is the characteristics of an ingredient or process step that might alert the CL and CCP
throughout the process flow in HACCP system. The manager of either shop or factory
who responsible to monitor the system should have provided with checklist and alert
their employee or colleagues to regularly check the quality of the product throughout
the production.

2.11 Principle 5: Establishment of Corrective Action

Corrective action is done for correcting a CCP process step or ingredients that
below critical limit. The corrective action is a strategy to solving the problem that may
grow during the production or as a guideline for maintenance of a machine or ways of
handling process under the HACCP system. If the action was done wrongly, it might
increase the risk of the problem in handling the product and cause the product to be
defected and have to be omitted and considered as wastages. The action always done
after value inspection of a product or raw material.

2.12 Principle 6: Establishment of Verification Process

This method and procedure are to test either the HACCP system is applicable
and suitable for the current food production process or it has to be fixed further. The

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verification will ensure the position and the quality of the HACCP system to work
efficiently without causing any increment of the problem.

There are several applications in verification e.g.:

• Evaluation of CCP remarks

• Evaluation of HACCP plan
• Determination of verification process schedule accurately

Verification process has to be done frequently as a routine to ensure the CCP

is always fit with the current situation.

2.13 Principle 7: Establishment of Record Keeping Procedure

Record-keeping procedure of HACCP system is covering the whole recorded

information of the system to allow the system maintain for several periods of time.
The record-keeping is consisting of CCP, CL, monitoring procedures of CL and its
signal, corrective action and its verification. It is important to record and keep the
recorded data for the operator use or as a prove to food inspector if there is external
audit.

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 SECTION 3

TERMS OF REFERENCE

The HACCP team shall address the potential of Biological, Chemical and Physical
hazard that will contaminate the product (i.e., meat pie) throughout the process of
receiving, handling, production, storage and distribution from the supplier of the
ingredients to the customers.

The HACCP study will oversee and take into consideration that the bakery operates
pre-requisite programmes that include:

• Supplier Approval Management

• Pest Control System
• Hygiene Regulation and Training
• Cleaning and Disinfection System
• Waste Management
• Pre-planned Maintenance
• Hygienic Premises Design
• Effective Temperature and Storage Condition
• Preparation and HACCP Team

The HACCP study will be formulated with various codes of practice and food
regulations and will be referring to the following food safety legislation and Codes of
Practice:

• Codex Alimentarius Commission

• Hazard Analysis and Critical Control Points
• Good Manufacturing Practice
• Sanitation Standard of Operating Procedures

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The HACCP team will study the HACCP scope below:

3.1 Operation Flow

The operation flow of the plan is divided into two parts which are preparation
of raw material and the process. The preparation of raw material comprised of the
receiving of ingredients from reputable supplier which will be proceeded with value
inspection from the receiving site. The process is the overall handling process after
raw material intake that comprised of weighing, mixing, cutting, frying, baking,
storage, packing and distribution which will be covered the whole process of
identifying CCP and CL since in this step, the raw material has been confirmed as
received.

3.2 Type of Hazards

The hazard that will be monitored in this system and process flow will be
addressed in Biological, Chemical and Physical Hazards (see 2.7). These hazards will
be measured its severity and its frequency (likelihood) to occur throughout the process
starting from the preparation of raw material to the distribution of the food.

3.3 Product Description

The meat pie is 30% breadfruit flour and 70% wheat flour for pastry, crumb
like texture, golden brown colour and 20% meat and shortenings, margarine. The meat
pie should be in between pH 4 and 7. Its compositions are meat, pastry, potato and
vegetable. The size of the pie is 10 x 10 x 3 centimetres from using pie tins.

3.4 Intended Use of the Products

The product is for directly and indirectly consume and freshly baked of the
current day. The cooking would be on the same day with a target customer group for
individual who wants to eat the product on the same day. However, they could store

15
the product in the fridge temperature under 4oC for 3-5 days by wrapping with
aluminium foil and reheat the product in microwave (800 watts) for 4 minutes.

3.5 Consumers including ‘At Risk’ Groups

The product is suitable for institutional caterers, event participants, family, or

local community surrounding. However, there is a risk for a group of people who
might be allergic to breadfruit since the meat pie contain 30% of breadfruit flour.

3.6 Packaging, Storage and Distribution

The packaging of the product is modified atmosphere packaging with O2 0%,

CO2 50% and N2 50% and has limited which is 1 1/2 day due to moisture migration
into pastry with temperature storage is under room temperature 25oC-30oC or 3-5 days
for temperature at 4oC in the fridge. The distribution of the product for more than a
half day would be in a chilled at 4oC and less than a half day at ambient temperature.

3.7 Processing and Safety Information

The processing involved weighing, kneading, frying, baking every day to

maintain the quality of the product. The expired product would be a wastage if more
than 5 days without any placement inside the fridge. The required shelf life is ‘best
before’ 2 days after manufacturing with suggestion of chilling the meat pie in the fridge
under 4oC to extend the shelf life and reheating for 4 minutes in microwave (800 watts)
as instruction label to avoid contamination of ready-to-eat meat pie. The information
also listed the ingredients of the product including the allergen information.

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 SECTION 4

MODEL OF HACCP PLAN OF MEAT PIE

4.1 Establishment of HACCP Team

NAME GROUP ROLE JOB TITLE JOB SCOPES

MUHAMMAD AIDIL WAFI BIN ADMINISTRATIVE HACCP LEADER TECHNICAL ESTABLISH HACCP TEAM,
ROSLI cum MANAGER CONDUCT AND MANAGE
ADMINISTRATOR cum QUALITY HACCP MEETINGS AND
ASSURANCE PROCESS, PRODUCE AND
TECHNICIAN RECORD HACCP PLAN.

MUTHIAH NURI RAHMANI ADMINISTRATIVE CHALLENGER QUALITY LEAD THE IDENTIFICATION

ASSURANCE OF WEAKNESSES IN THE
MANAGER HACCP SYSTEM.

NOR HAIZAADIELA BINTI TECHNICAL PRODUCT TECHNICAL PROVIDE DETAILED

ABDUL RAHMAN SPECIALIST MANAGER UNDERSTANDING OF THE
PRODUCT RECIPES, DESIGN,
PROCESS AND STATUS OF
THE PRACTICE
THROUGHOUT THE
PROCESS.

MUHAMMAD AJWAD BIN TECHNICAL FOOD LABORATORY ASSIST AND ADVICE TEAM
MOHD SALLEH MICROBIOLOGIST MANAGER WITH MICROBIOLOGICAL
cum HYGIENE cum MATTERS RELATED TO
SPECIALIST TECHNICAL FOOD, HYGIENIC DESIGN
MANAGER AND LAYOUT.

NOOR INTAN SHAMIMI BINTI TECHNICAL FOOD TECHNICAL ASSIST AND ADVICE TEAM
ABDUL HAMID TECHNOLOGIST MANAGER WITH TECHNOLOGY AND
FOOD SCIENCE MATTERS
Table 4.1 HACCP Team

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 4.2 Product Description

Name of product Meat Pie

Composition Meat, pastry, potato, vegetable
Product Characteristics 30% breadfruit flour and 70% wheat flour for pastry, crumb like texture, golden brown
colour, 20% meat, addition of shortenings (margarine)
Allergen information: breadfruit flour.
Methods of Processing Cooking, Baking, Cooling, Reheating
Tools:
- Pressure Cooker 15 psi, 6-7 minutes/pound,
- Oven, 180oC for 30 minutes (incl. preheating)
- Microwave 700 watt ~ 350oC, 1-2 minutes
Methods of Preservation Remain at 25oC-30oC for under 1 ½ day or keep in a fridge at 4oC
Primary Packaging Modified Atmosphere Packaging
Gas composition: 0% of O2, 50% of CO2, 50% of N2
Tools:
- MAP Tray Sealer Machine,
- Modified Atmosphere Gas Analyser
Conditions of Storage Dry storage: 25oC – 30oC
Cold storage: 4oC
Method of Distribution Distribution under ½ day: storage under 25oC – 30oC
Distribution above ½ day: storage under 4oC
Shelf life Dry storage: 25oC – 30oC for 1 ½ day
Cold storage: 4oC for 3-5 days
Specific Labelling Name of the food, list of ingredients, allergen information, Quantitative declaration of
ingredients (QUID), net quantity, storage conditions, date labelling, name and address of
manufacturer, country of origin or place of provenance, preparation instructions,
nutritional declaration
Instruction on the label - Kept in the fridge at maximum 4oC (should be eaten within 5 days after the seal has
been opened and kept in the fridge).
- Reheating using microwave 800 watt (~ 450oC) for 4 minutes for the chilled meat
pie by wrapping them in the foil.
Table 4.2 Product Description

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 4.3 Identification of the Product’s Intended Use

Name of product Meat pie

Intended use Directly consumed – in bakery or nearby local retail consumer.
Indirectly consumed – chilled meat pie
Target consumer Institutional caterers, event participants, family, local community surrounding
regardless of age groups.

Not suitable:
- New born (0-2 months)
- Infant (2 months – 1 year)
- Toddler (1 – 4 year)
- Breadfruit allergy individuals
Table 4.3 Identification of the Product’s Intended Use

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4.4 Meat Pie Process Flow Diagram

Figure 4.1 Meat Pie Process Flow Diagram

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4.5 On-Site Confirmation of Flow Diagram: Meat Pie

Figure 4.2 On-Site Confirmation of Flow Diagram: Meat Pie

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 4.6 Principle 1: Hazard Analysis

Steps Ingredients Potential Hazards Reasonably Severity Significant Preventive or Control Measure
Hazard likely to (L/M/H) Hazard
(B/C/P) occur (Y/N)
*(L/M/H)
Receiving Minced beef Spoilage or contamination of raw L M N • Reputable Suppliers: Quality
B minced beef with Escherichia coli Assurance Certificate from
or Salmonella sp. Suppliers
Bone pieces left in the beef, and L M N
P foreign materials from packaging
material (plastic pieces)
Carrot Unfreshened carrot or L M N
B contamination by mould – Botrytis
sp. or Sclerotinia sp.
Agricultural chemicals such as L M N
C
pesticides, herbicides
P Soil residues from agriculture L M N

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 Eggs Rotten eggs or contamination with L M N
B
Salmonella sp.
Presence of foreign material like M L N
C
feathers
Margarine Spoilage or contamination by L M N
B
Listeria monocytogenes
Foreign materials from packaging L M N
P
(plastic pieces)
Breadfruit flour Contaminated yeast (by spoilage L M N
B
or pathogenic MO)
Wheat flour Contaminated yeast (by spoilage L M N
B
or pathogenic MO)
Irish Potato B The bacterium Erwinia carotovora L M N
Solanine poisoning which are L M N
C
produces from the potato
Medium onion Caused by Alternaria porri, a L M N
B
fungus affecting tops and bulbs

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Storage Minced beef Spoilage or contamination of raw L M N • Low storage temperature
B minced beef with Escherichia coli (<7oC)
or Salmonella sp.
Foreign materials from packaging L M N • Monitor cleaning process to
P material (plastics pieces) ensure no foreign material is
present
Carrot Contamination by mould – L M N • Low storage temperature
B Botrytis sp. or Sclerotinia sp. (≤4oC)

Agricultural chemicals such as M M Y • Monitor cleaning process to

C pesticides, herbicides ensure no foreign material is
present
Soil residues from agriculture L M N • Monitor cleaning process to
P ensure no foreign material is
present
Eggs Contamination with Salmonella sp. L M N • Low storage temperature
B (<7oC)

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 Presence of foreign material like M L N • Monitor cleaning process to
P feathers ensure no foreign material is
present
Margarine Spoilage or contamination by L M N • Low storage temperature
B Listeria monocytogenes (≤4oC)

Foreign materials from packaging L M N • Monitor cleaning process to

P material (plastics pieces) ensure no foreign material is
present
Irish Potato Soft rot caused by Clavibacter M M Y • Store at room temperature.
B
michiganensis
Solanine poisoning which are L M N • Keep in dark, cool and dry
C
produces from the potato storage
Breadfruit flour Insect L M Y • Proper storage conditions (dry,
B clean), sealed packaging of the
ingredients.
Wheat flour Insect L M Y • Proper storage conditions (dry,
B clean), sealed packaging of the
ingredients.

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 Medium onion Purple Blotch caused by the M M Y • Store at room temperature.
B
fungus Botrytis allii
Cutting Irish potato B Food handling L M N • Medical Check
Medium onions B Food handling L M N • Practice SSOP
Weighing All B Food handling L M N • Practice Hygiene Regulation
Mixing Dough B Food handling L M N and Training
Storage Irish potato Soft rot caused by Clavibacter L M N • Maintaining a cool (1-3oC) dry
(leftover) B michiganensis environment in the storage
facility.
Medium onions Purple Blotch caused by the L M N • Maintaining a cool (1-3oC) dry
B fungus Botrytis allii. environment in the storage
facility.
Addition Water Contamination of pathogen L M N • Ensure the filtered water are
B
used
Presence of any chemicals residue M M N • Ensure water distribution and
C from water source (rust from pipe pipe system cleanliness
system)

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Kneading Dough Presence of unwanted materials M M N • Apply Good Manufacturing
P such as hair and nail from the food Practices
handler
Rolling Dough Food handling L M N • Medical Check
• Practice SSOP
B
• Practice Hygiene Regulation
and Training
Presence of unwanted materials M M N • Apply Good Manufacturing
P such as hair and nail from the food Practices
handler
Filling Dough Presence of unwanted materials M M N • Apply Good Manufacturing
P such as hair and nail from the food Practices
handler
Cooking Minced beef Survival of Escherichia coli or M H Y • Ensure cooking temperature
B
Salmonella sp. above 75oC
Presence of foreign materials such M M N • Monitor the cooking process to
as human hair ensure no foreign material is
P
present and apply Good
Manufacturing Practices

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 Carrot Unfreshened or contaminated M M N • Ensure storage temperatures
are maintained at a maximum
B of 4oC
• Ensure cooking temperature
above 75oC
Enclosing Egg Rotten or contaminated L M N • Ensure storage temperatures
are maintained at a maximum
B
of 4oC
• Ensure the smell of the egg.
Baking Fried minced Survival of Escherichia coli or M H Y • Ensure baking temperature
B
beef Salmonella sp. above 100oC
Fraction any metal or instruments M M Y • Visual inspection to during
during the process baking process to ensure no
P foreign material is present.
• Regular routine equipment
maintenance.
Meat pie B Pathogen bacteria M H Y • Ensure baking temperature
above 100oC

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Cooling Fried minced Contamination of another H M Y • Ensure time taken for cooling
B
beef pathogen less than 2 hours.
Contamination by dust particles M M Y • Ensure cleanliness of the
C
surrounding
Meat pie Contamination of another H M Y • Ensure time taken for cooling
B
pathogen less than 2 hours
Packaging Fried minced Contamination of mould H M Y • Ensure the composition of
B
beef oxygen = 0%.
Hazardous chemicals from plastic L M N • Monitor the packaging used
packaging • Ensure the use laminated film
cellulose-polyethylene-
C
cellulose
• Packaging supplied from
reputable supplier
Meat pie B Contamination of another H M Y • Undergo inspection before
pathogen packing
Storage Fried minced Contamination of another H M Y • Ensure storage temperatures
beef B pathogen are maintained at a maximum
of 4oC

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 Meat pie Contamination of another H M Y • Ensure storage temperatures

B pathogen are maintained at a maximum

of 4oC

Display Meat pie Contamination of another H H Y • Ensure display case

B pathogen temperature are in range of
25oC – 30oC
Reheating Meat pie Contamination of another H M Y • Ensure reheat temperature
pathogen above 75oC
B
• Ensure centre temperature at
least 75oC

Presence of foreign materials from M L N • Apply Good Manufacturing

P Packaging pieces or human hair
Practices
Table 4.4 Principle 1: Hazard Analysis

30
 4.7 Principle 2: Establishment of Critical Control Point

4.7.1 Critical Control Point: Ingredient

Ingredients Potential Hazard P1 P2 P3 CCP

Minced beef B Y Y Y Y

P Y Y N N

C Y Y N N

Carrot B Y Y Y Y

C Y Y N N

P Y Y N N

Egg B Y Y Y Y

P Y Y N N

Margarine B Y Y Y Y

Breadfruit flour B Y Y N N

Wheat flour B Y Y N N

Irish Potato B Y Y Y Y

31
 C Y Y Y Y

Medium onion B Y Y Y Y
P1: Is there a danger in this raw material?
P2: Will the process or the consumer eliminate the danger?
P3: Is there a risk of cross-contamination of the facility or other uncontrollable products?
CCP: Critical control point.

Table 4.5 Critical Control Point: Ingredient

32
 4.7.2 Critical Control Point: Process Step

Process Step Potential Hazard P1 P2 P3 CCP

Receiving B Y Y N N

Storage B Y Y Y Y

Weighing B Y Y N N

P N - - N

Mixing B N - - N

P N - - N

Addition of water B Y Y N N

Cutting B Y Y N N

C N - - N

Kneading B N - - N

P N - - N

Cooking B Y Y Y Y

Rolling B Y Y N N

33
 P Y N N N

Filling B Y Y N N

P Y N N N

Enclosing B Y Y N N

P Y Y N N

Baking B Y Y Y Y

P Y Y N N

Cooling B Y Y Y Y

C Y Y N N

Packaging B Y Y Y Y

Storage B Y Y Y Y

C Y N - N

Display B Y Y Y Y

C Y N - N

Reheating B Y Y Y Y

P Y Y N N

34
 C Y N - N
P1: Does this step involve a hazard of sufficient risk and severity to warrant it control?
P2: Does a control measure for the hazard exist at this step?
P3: Is control at this step necessary to prevent, eliminate or reduce the risk of hazard to consumers?
CCP: Critical control point.
Table 4.6 Critical Control Point: Process Step

35
 4.8 Principle 3: Establishment of Critical Limit

Ingredient/Process Step CCP No. Critical Limit

Minced beef 1(B) Spoiled beef = 0, T = ≤ 6oC

Eggs 2(B) Label expired date, rotten egg = 0, T = ≤ 6oC

Carrots 3(B) Unfreshened carrot = 0, T = ≤ 4oC

Margarine 4(B) Label expired date, T = ≤ 4oC

Irish Potato 5(B) Wet spots = 0

6(C) Solanine level = <0.555%, store at dark room storage

Medium onion 7(B) Humidity = 65-70%

Storage 8(B) Dry storage T = (25oC – 30oC), cold storage T = ≤ 4oC

Cooking 9(B) Cooking temperature = ≥ 76oC, centre temperature = ≥ 75oC

Baking 10(B) Baking temperature = ≥ 101oC

Cooling 11(B) Cooling period = 90 minutes (< 2 hrs)

Packaging 12(B) Composition of gas; O2 = 0%, CO2 = 50%, N2 = 50%

Holding time = <10 minutes, T= 25oC – 30oC

Storage 13(B) T = ≤ 4o C

36
Display 14(B) T = (25oC – 30oC), Period: < 2 days

Reheating 15(B) Reheating temperature = ≥ 76oC, centre temperature = ≥ 75oC

Table 4.7 Principle 3: Establishment of Critical Limit

37
 4.9 Principle 4: Establishment of Monitoring Procedure

Ingredient/ CCP No. CL Monitoring Procedures

Process Step
What How Where Who Frequency

Minced Beef 1(B) Spoiled beef = 0, • Smelly beef • Perform a smell • Receiving site • Receiving • Every receiving
T = ≤ 6o C • Delivery/storage test • Delivery truck personnel • Every before opening
temperature • Check and storage • Bakery and closing
delivery/storage manager
temperature

Eggs 2(B) Label expired • Smelly eggs • Perform a smell • Receiving site • Receiving • Every receiving
date, • Delivery/storage test • Delivery truck personnel • Every before opening
Rotten egg = 0, temperature • Check and storage • Bakery and closing
T = ≤ 6o C delivery/storage • Kitchen manager • Every enclosing
temperature • Baking process
• Check expiry personnel
date
• Perform a
floating test

Carrots 3(B) Unfreshened • Dark spot, soft, • Perform a sight • Receiving site • Receiving • Every receiving
carrot = 0, smelly carrots test, feel test, • Delivery truck personnel • Every before opening
T = ≤ 4o C • Delivery/storage and smell test and storage • Bakery and closing
temperature • Kitchen manager • Every cooking process

38
 • Check • Cooking
delivery/storage personnel
temperature

Margarine 4(B) Label expired • Discoloration, • Check expiry • Receiving site • Receiving • Every receiving
date, T = ≤ 4oC mould, sour date • Delivery truck personnel • Every before opening
smell, bad taste • Perform a sight and storage • Bakery and closing
• Delivery/storage test and smell • Kitchen manager • Every mixing process
temperature test • Bakery
• Check personnel
delivery/storage
temperature

Irish Potato 5(B) Wet spots = 0 • Lesions on the • Perform a sight • Storage • Receiving • Every receiving
tubes as slightly test, feel test. personnel • Every before opening
sunken, brown, • • Bakery and closing
wet. manager

6(C) Solanine level = • Green colour in • Perform a sight • Receiving site • Receiving • Every before opening
<0.555%, tuber and test • Storage personnel and closing
store at dark sprouted • Perform • Laboratory • Food • Semi-annually
room storage solanine level microbiologist
test analysis

Medium onion 7(B) Humidity = 65- • Turn from brown • Perform a sight • Storage • Receiving • Every before opening
70% to purple with a test, feel test. personnel and closing
halo of yellow. • Check humidity • Bakery
level manager

39
Storage 8(B) Dry storage T = • Storage • Check storage • Storage • Bakery • Every before opening
(25oC – 30oC), temperature temperature manager and closing
cold storage T =
≤ 4 oC

Cooking 9(B) Cooking • Cooking • Check cooking • Kitchen • Cooking • Every cooking process
temperature temperature temperature personnel
= ≥ 76oC

Baking 10(B) Baking • Baking • Pre-heat baking • Kitchen • Baking • Every baking process
temperature = ≥ temperature temperature personnel
101oC • Check baking
temperature

Cooling 11(B) Cooling period = • Time • Check time • Kitchen • Baking • Every cooling process
90 minutes management period personnel
(< 2 hrs) • Surrounding • Ensure the
conditions cleanliness
surrounding
conditions,
SSOP

Packaging 12(B) Composition of • Composition of • Ensure the • Kitchen • Packaging • Every packaging
gas; O2 = 0%, gas present. composition of personnel processes
CO2 = 50%, N2 • Handling period the gas present • Bakery • Every day
= 50%, • Surrounding in the manager
conditions packaging.

40
 holding time = • Check the time
<10 minutes, and work faster
T= 25oC – 30oC • Check
surrounding
temperature
• Ensure the
cleanliness
surrounding
conditions,
SSOP

Storage 13(B) T = ≤ 4o C • Storage • Check storage • Storage • Bakery • Every before opening
temperature temperature manager and closing

Display 14(B) T = (25oC – • Display case • Check display • Display case • Bakery • Every before opening
30oC) temperature case manager and closing
Period: < 2 days temperature • Cashier

Reheating 15(B) Reheating • Reheating • Check • Kitchen • Baking • Every reheating

temperature temperature reheating personnel • Every serving
= ≥ 76oC, • Centre temperature of
centre temperature of the microwave
temperature product • Check centre
= ≥ 75oC temperature of
product after
reheating
Table 4.8 Principle 4: Establishment of Monitoring Procedure

41
 4.10 Principle 5: Establishment of Corrective Action

Ingredient/ CCP No. CL Monitoring Procedures Corrective

Process Action
Step What How Where Who Frequency

Minced 1(B) Spoiled beef • Smelly beef • Perform a smell • Receiving • Receiving • Every • Return deliveries that do not meet
Beef = 0, • Delivery/storage test site personnel receiving quality standard during receiving
T = ≤ 6 oC temperature • Check • Delivery • Bakery • Every before • Discard spoiled beef at bakery as
delivery/storage truck and manager opening and wastage
temperature storage closing • Preventive maintenance of storage to
keep its efficiency monthly

Eggs 2(B) Label • Smelly eggs • Perform a smell • Receiving • Receiving • Every • Return deliveries that do not meet
expired date, • Delivery/storage test site personnel receiving quality standard during receiving
Rotten egg temperature • Check • Delivery • Bakery • Every before • Discard spoiled egg at bakery as
= 0, delivery/storage truck and manager opening and wastage
T = ≤ 6oC temperature storage • Baking closing • Preventive maintenance of storage to
• Check expiry • Kitchen personnel • Every keep its efficiency monthly
date enclosing
• Perform a process
floating test

Carrots 3(B) Unfreshened • Dark spot, soft, • Perform a sight • Receiving • Receiving • Every • Return deliveries that do not meet
carrot = 0, smelly carrots test, feel test, site personnel receiving quality standard during receiving
T = ≤ 4oC • Delivery/storage and smell test • Delivery • Bakery • Every before • Discard unfreshened carrot at bakery
temperature • Check truck and manager opening and as wastage
delivery/storage storage • Cooking closing • Preventive maintenance of storage to
temperature • Kitchen personnel keep its efficiency monthly

42
 • Every cooking
process

Margarine 4(B) Label • Discoloration, • Check expiry • Receiving • Receiving • Every • Return deliveries that do not meet
expired date, mould, sour date site personnel receiving quality standard during receiving
T = ≤ 4 oC smell, bad taste • Perform a sight • Delivery • Bakery • Every before • Discard spoiled margarine at bakery
• Delivery/storage test and smell truck and manager opening and as wastage
temperature test storage • Bakery closing • Preventive maintenance of storage to
• Check • Kitchen personnel • Every mixing keep its efficiency monthly
delivery/storage process
temperature

Irish 5(B) Wet spots = • Lesions on the • Perform a sight • Storage • Receiving • Every • Return deliveries that do not meet
Potato 0 tubes as slightly test, feel test. personnel receiving quality standard during receiving
sunken, brown, • Bakery • Every before • Discard spoiled potato at bakery as
wet. manager opening and wastage
closing

6(C) Solanine • Green colour in • Perform a • Receiving • Receiving • Every before • Discard the defective potato
level = tuber and sight test site personnel opening and • Make a report
<0.555%, sprouted • Perform • Storage • Food closing
store at dark microbiologist • Semi-
solanine level • Laboratory
room
test analysis annually
storage

Medium 7(B) Humidity = • Turn from • Perform a sight • Storage • Receiving • Every before • Return deliveries that do not meet
onion 65-70% brown to purple test, feel test. personnel opening and quality standard during receiving
with a halo of • Check humidity • Bakery closing
• Discard spoiled onion at bakery as
yellow. level manager wastage

43
Storage 8(B) Dry storage • Storage • Check storage • Storage • Bakery • Every before • Check the temperature using
T = (25oC – temperature temperature manager opening and temperature calibrator
30oC), cold closing • Preventive maintenance of storage to
storage T = keep its efficiency monthly
≤ 4 oC • Perform chemical washing on heat
exchanger annually

Cooking 9(B) Cooking • Cooking • Check cooking • Kitchen • Cooking • Every cooking • Check the temperature of product
temperature temperature temperature personnel process using digital food cooking
= ≥ 76oC thermometer and meat food
thermometer
• Ensure the accuracy of digital food
cooking thermometer and meat food
thermometer

Baking 10(B) Baking • Baking • Pre-heat baking • Kitchen • Baking • Every baking • Pre-heat oven before baking
temperature temperature temperature personnel process • Check the temperature of oven using
= ≥ 101oC • Check baking oven thermometer
temperature

Cooling 11(B) Cooling • Time • Check time • Kitchen • Baking • Every cooling • Check the temperature of product
period = 90 management period personnel process using digital food cooking
minutes • Surrounding • Ensure the thermometer
(< 2 hrs) conditions cleanliness • Check the time by using digital time
surrounding stopper
conditions,
SSOP

Packaging 12(B) Composition • Composition of • Ensure the • Kitchen • Packaging • Every • Check the composition of gas by
of gas; O2 = gas present. composition of personnel packaging using modified atmosphere gas
0%, CO2 = • Handling period the gas present processes analyser

44
 50%, N2 = • Surrounding in the • Bakery • Every day
50%, conditions packaging. manager
holding time • Check the time
= <10 and work faster
minutes, • Check
T= 25oC – surrounding
30oC temperature
• Ensure the
cleanliness
surrounding
conditions,
SSOP

Storage 13(B) T = ≤ 4 oC • Storage • Check storage • Storage • Bakery • Every before • Check the temperature using
temperature temperature manager opening and temperature calibrator
closing • Preventive maintenance of storage to
keep its efficiency monthly
• Perform chemical washing on heat
exchanger annually

Display 14(B) T = (25oC – • Display case • Check display • Display • Bakery • Every before • Reheat the products every serving
30oC) temperature case case manager opening and • Visual inspection on the product
Period: < 2 temperature • Cashier closing displayed before serving
days • Ensure the quality of the products
• Discard product above 2 days

Reheating 15(B) Reheating • Reheating • Check • Kitchen • Baking • Every • Ensure the packaging of the meat pie
temperature temperature reheating personnel reheating is opened before reheating
= ≥ 76oC, • Centre temperature of • Every serving • Ensure the meat pie is wrapped by
centre temperature of the microwave aluminium foils
temperature product

45
= ≥ 75oC • Check centre • Check the centre temperature by
temperature of using digital food cooking
product after thermometer before serving
reheating
Table 4.9 Principle 5: Establishment of Corrective Action

46
 4.11 Principle 6: Establishment of Verification Process

Ingredient/ CCP No. CL Monitoring Procedures Corrective Verification Process

Process Step Action
What How Where Who Frequency

Minced Beef 1(B) Spoiled beef • Smelly beef • Perform a smell • Receiving • Receiving • Every receiving • Return deliveries that • Microbes analysis of
= 0, • Delivery/storage test site personnel • Every before do not meet quality ingredients annually
T = ≤ 6oC temperature • Check • Delivery • Bakery opening and standard during • Customer complaint
delivery/storage truck and manager closing receiving • Reviewing records on
temperature storage • Discard spoiled beef at regular basis
bakery as wastage
• Preventive
maintenance of storage
to keep its efficiency
monthly

Eggs 2(B) Label • Smelly eggs • Perform a smell • Receiving • Receiving • Every receiving • Return deliveries that • Microbes analysis of
expired date, • Delivery/storage test site personnel • Every before do not meet quality ingredients annually
Rotten egg = temperature • Check • Delivery • Bakery opening and standard during • Customer complaint
0, delivery/storage truck and manager closing receiving • Reviewing records on
T = ≤ 6oC temperature storage • Baking • Every enclosing • Discard spoiled egg at regular basis
• Check expiry • Kitchen personnel process bakery as wastage
date • Preventive
• Perform a maintenance of storage
floating test to keep its efficiency
monthly

Carrots 3(B) Unfreshened • Dark spot, soft, • Perform a sight • Receiving • Receiving • Every receiving • Return deliveries that • Microbes analysis of
carrot = 0, smelly carrots test, feel test, site personnel • Every before do not meet quality ingredients annually
T = ≤ 4oC • Delivery/storage and smell test • Bakery opening and standard during • Customer complaint
temperature manager closing receiving

47
 • Check • Delivery • Cooking • Every cooking • Discard unfreshened • Reviewing records on
delivery/storage truck and personnel process carrot at bakery as regular basis
temperature storage wastage
• Kitchen • Preventive
maintenance of storage
to keep its efficiency
monthly

Margarine 4(B) Label • Discoloration, • Check expiry • Receiving • Receiving • Every receiving • Return deliveries that • Microbes analysis of
expired date, mould, sour date site personnel • Every before do not meet quality ingredients annually
T = ≤ 4oC smell, bad taste • Perform a sight • Delivery • Bakery opening and standard during • Customer complaint
• Delivery/storage test and smell truck and manager closing receiving • Reviewing records on
temperature test storage • Bakery • Every mixing • Discard spoiled regular basis
• Check • Kitchen personnel process margarine at bakery as
delivery/storage wastage
temperature • Preventive
maintenance of storage
to keep its efficiency
monthly

Irish Potato 5(B) Wet spots = • Lesions on the • Perform a sight • Storage • Receiving • Every receiving • Return deliveries that • Microbes analysis of
0 tubes as slightly test, feel test. personnel • Every before do not meet quality ingredients annually
sunken, brown, • Bakery opening and standard during • Customer complaint
wet. manager closing receiving • Reviewing records on
regular basis
• Discard spoiled
potato at bakery as
wastage

6(C) Solanine • Green colour in • Perform a sight • Receiving • Receiving • Every before • Reviewing records on
level = tuber and test site personnel opening and
• Discard the defective regular basis
potato
<0.555%, sprouted • Perform • Storage • Food closing • Perform solanine level
• Make a report
store at dark solanine level • Laboratory microbiologist • Semi-annually test analysis semi-
test analysis annually

48
 room
storage

Medium 7(B) Humidity = • Turn from • Perform a sight • Storage • Receiving • Every before • Return deliveries that • Microbes analysis of
onion 65-70% brown to purple test, feel test. personnel opening and do not meet quality ingredients annually
with a halo of • Check humidity • Bakery closing standard during • Customer complaint
yellow. level manager receiving • Reviewing records on
regular basis
• Discard spoiled onion
at bakery as wastage

Storage 8(B) Dry storage • Storage • Check storage • Storage • Bakery • Every before • Check the temperature • Calibration of
T = (25oC – temperature temperature manager opening and using temperature thermometer weekly
30oC), cold closing calibrator • Reviewing records on
storage T = • Preventive regular basis
≤ 4 oC maintenance of storage
to keep its efficiency
monthly
• Perform chemical
washing on heat
exchanger annually

Cooking 9(B) Cooking • Cooking • Check cooking • Kitchen • Cooking • Every cooking • Check the temperature • Calibration of
temperature temperature temperature personnel process of product using thermometer weekly
= ≥ 76oC digital food cooking • Reviewing records on
thermometer and meat regular basis
food thermometer
• Ensure the accuracy of
digital food cooking
thermometer and meat
food thermometer

49
Baking 10(B) Baking • Baking • Pre-heat baking • Kitchen • Baking • Every baking • Pre-heat oven before • Calibration of
temperature temperature temperature personnel process baking thermometer weekly
= ≥ 101oC • Check baking • Check the temperature • Reviewing records on
temperature of oven using oven regular basis
thermometer

Cooling 11(B) Cooling • Time • Check time • Kitchen • Baking • Every cooling • Check the temperature • Calibration of
period = 90 management period personnel process of product using thermometer weekly
minutes • Surrounding • Ensure the digital food cooking • Reviewing records on
(< 2 hrs) conditions cleanliness thermometer regular basis
surrounding • Check the time by
conditions, using digital time
SSOP stopper

Packaging 12(B) Composition • Composition of • Ensure the • Kitchen • Packaging • Every • Check the composition • Calibration of MAP
of gas; O2 = gas present. composition of personnel packaging of gas by using machine annually
0%, CO2 = • Handling period the gas present • Bakery processes modified atmosphere • Reviewing records on
50%, N2 = • Surrounding in the manager • Every day gas analyser regular basis
50%, conditions packaging.
holding time • Check the time
= <10 and work faster
minutes, • Check
T= 25oC – surrounding
30oC temperature
• Ensure the
cleanliness
surrounding
conditions,
SSOP

Storage 13(B) T = ≤ 4oC • Storage • Check storage • Storage • Bakery • Every before • Check the temperature • Calibration of
temperature temperature manager opening and using temperature thermometer weekly
closing calibrator

50
 • Preventive • Reviewing records on
maintenance of storage regular basis
to keep its efficiency
monthly
• Perform chemical
washing on heat
exchanger annually

Display 14(B) T = (25oC – • Display case • Check display • Display • Bakery • Every before • Reheat the products • Calibration of display
30oC) temperature case case manager opening and every serving case temperature
Period: < 2 temperature • Cashier closing • Visual inspection on • Reviewing records on
days the product displayed regular basis
before serving • Customer complaint
• Ensure the quality of
the products
• Discard product above
2 days

Reheating 15(B) Reheating • Reheating • Check • Kitchen • Baking • Every reheating • Ensure the packaging • Calibration of
temperature temperature reheating personnel • Every serving of the meat pie is thermometer weekly
= ≥ 76oC, • Centre temperature of opened before • Reviewing records on
centre temperature of the microwave reheating regular basis
temperature product • Check centre • Ensure the meat pie is
= ≥ 75oC temperature of wrapped by aluminium
product after foils
reheating • Check the centre
temperature by using
digital food cooking
thermometer before
serving
Table 4.10 Principle 6: Establishment of Verification Process

51
 4.12 Principle 7: Establishment of Record-Keeping Procedure

Ingredient/ CCP CL Monitoring Procedures Corrective Verification Process Records

Process No. Action
Step What How Where Who Frequency

Minced 1(B) Spoiled beef • Smelly beef • Perform a smell • Receiving • Receiving • Every receiving • Return deliveries • Microbes • Delivery temperature (record
Beef = 0, • Delivery/storage test site personnel • Every before that do not meet analysis of on receiving log)
T = ≤ 6oC temperature • Check • Delivery • Bakery opening and quality standard ingredients • Return ingredients (record
delivery/storage truck and manager closing during receiving annually on receiving log)
temperature storage • Discard spoiled • Customer • Microbe analysis status
beef at bakery as complaint (record on production log)
wastage • Reviewing • Storage temperature (record
• Preventive records on on bakery log)
maintenance of regular basis • Customer complaint (record
storage to keep its on customer satisfaction
efficiency monthly document)

Eggs 2(B) Label expired • Smelly eggs • Perform a smell • Receiving • Receiving • Every receiving • Return deliveries
date, • Delivery/storage test site personnel • Every before that do not meet
Rotten egg = temperature • Check • Delivery • Bakery opening and quality standard
0, delivery/storage truck and manager closing during receiving
T = ≤ 6oC temperature storage • Baking • Every enclosing • Discard spoiled
• Check expiry • Kitchen personnel process egg at bakery as
date wastage
• Perform a • Preventive
floating test maintenance of
storage to keep its
efficiency monthly

Carrots 3(B) Unfreshened • Dark spot, soft, • Perform a sight • Receiving • Receiving • Every receiving • Return deliveries
carrot = 0, smelly carrots test, feel test, site personnel • Every before that do not meet
T = ≤ 4oC • Delivery/storage and smell test • Delivery • Bakery opening and quality standard
temperature truck and manager closing during receiving
storage

52
 • Check • Kitchen • Cooking • Every cooking • Discard
delivery/storage personnel process unfreshened carrot
temperature at bakery as
wastage
• Preventive
maintenance of
storage to keep its
efficiency monthly

Margarine 4(B) Label expired • Discoloration, • Check expiry • Receiving • Receiving • Every receiving • Return deliveries • Microbes • Delivery temperature (record
date, T = ≤ mould, sour date site personnel • Every before that do not meet analysis of on receiving log)
4oC smell, bad taste • Perform a sight • Delivery • Bakery opening and quality standard ingredients • Return ingredients (record
• Delivery/storage test and smell truck and manager closing during receiving annually on receiving log)
temperature test storage • Bakery • Every mixing • Discard spoiled • Customer • Microbe analysis status
• Check • Kitchen personnel process margarine at complaint (record on production log)
delivery/storage bakery as wastage • Reviewing • Storage temperature (record
temperature • Preventive records on on bakery log)
maintenance of regular basis • Customer complaint (record
storage to keep its on customer satisfaction
efficiency monthly document)

Irish Potato 5(B) Wet spots = 0 • Lesions on the • Perform a sight • Storage • Receiving • Every receiving • Return deliveries • Microbes • Return ingredients (record
tubes as slightly test, feel test. personnel • Every before that do not meet analysis of on receiving log)
sunken, brown, • Bakery opening and quality standard ingredients • Microbes analysis status
wet. manager closing during receiving annually (record on production log)
• Customer • Customer complaint (record
• Discard spoiled complaint on customer satisfaction
potato at bakery • Reviewing document)
as wastage records on
regular basis

6(C) Solanine • Green colour in • Perform sight • Receiving • Receiving • Every before • Reviewing • Return ingredients (record
level = tuber and test site personnel opening and • Discard the records on on receiving log)
<0.555%, sprouted • Storage closing defective potato regular basis • Solanine level status (record
store at dark • Make a report • Perform on production log)
room storage solanine level

53
 test analysis • Storage temperature (record
semi-annually on bakery log)

Medium 7(B) Humidity = • Turn from brown • Perform a sight • Storage • Receiving • Every before • Return deliveries • Microbes • Microbe analysis status
onion 65-70% to purple with a test, feel test. personnel opening and that do not meet analysis of (record on production status)
halo of yellow. • Check humidity • Bakery closing quality standard ingredients • Storage humidity level
level manager during receiving annually (record on bakery log)
• • Customer • Customer complaint (record
• Discard spoiled complaint on customer satisfaction
onion at bakery • Reviewing document)
as wastage records on
regular basis

Storage 8(B) Dry storage T • Storage • Check storage • Storage • Bakery • Every before • Check the • Calibration of • Storage temperature (record
= (25oC – temperature temperature manager opening and temperature using thermometer on bakery log)
30oC), cold closing temperature weekly
storage T = ≤ calibrator • Reviewing
4oC • Preventive records on
maintenance of regular basis
storage to keep its
efficiency monthly
• Perform chemical
washing on heat
exchanger
annually

Cooking 9(B) Cooking • Cooking • Check cooking • Kitchen • Cooking • Every cooking • Check the • Calibration of • Batch temperature (record on
temperature temperature temperature personnel process temperature of thermometer production log)
= ≥ 76oC product using weekly
digital food • Reviewing
cooking records on
thermometer and regular basis
meat food
thermometer
• Ensure the
accuracy of digital
food cooking

54
 thermometer and
meat food
thermometer

Baking 10(B) Baking • Baking • Pre-heat baking • Kitchen • Baking • Every baking • Pre-heat oven • Calibration of • Batch temperature (record on
temperature = temperature temperature personnel process before baking thermometer production log)
≥ 101oC • Check baking • Check the weekly
temperature temperature of • Reviewing
oven using oven records on
thermometer regular basis

Cooling 11(B) Cooling • Time • Check time • Kitchen • Baking • Every cooling • Check the • Calibration of • Microbe analysis status
period = 90 management period personnel process temperature of thermometer (record on production log)
minutes • Surrounding • Ensure the product using weekly • Batch temperature (record
(< 2 hrs) conditions cleanliness digital food • Reviewing on production log)
surrounding cooking records on
conditions, thermometer regular basis
SSOP • Check the time • Microbe
analysis of
products
annually

Packaging 12(B) Composition • Composition of • Ensure the • Kitchen • Packaging • Every • Check the • Calibration of • Batch production (records on
of gas; O2 = gas present. composition of personnel packaging composition of MAP machine production log)
0%, CO2 = • Handling period the gas present • Bakery processes gas by using annually
50%, N2 = • Surrounding in the packaging. manager • Every day modified • Reviewing on
50%, conditions • Check the time atmosphere gas regular basis
holding time and work faster analyser
= <10 • Check
minutes, surrounding
T= 25oC – temperature
30oC • Ensure the
cleanliness
surrounding
conditions,
SSOP

55
Storage 13(B) T = ≤ 4oC • Storage • Check storage • Storage • Bakery • Every before • Check the • Check the • Storage temperature (record
temperature temperature manager opening and temperature using temperature on bakery log)
closing temperature using
calibrator temperature
• Preventive calibrator
maintenance of • Preventive
storage to keep its maintenance of
efficiency monthly storage to keep
• Perform chemical its efficiency
washing on heat monthly
exchanger • Perform
annually chemical
washing on heat
exchanger
annually

Display T = (25oC – • Display case • Check display • Display • Bakery • Every before • Reheat the • Calibration of • Date of batches displayed
14(B) 30oC) temperature case temperature case manager opening and products every display case (records on production log)
Period: < 2 • Cashier closing serving temperature • Display case temperature
days • Visual inspection • Reviewing (record on bakery log)
on the product records on • Customer complaint (record
displayed before regular basis on customer satisfaction
serving • Customer document)
• Ensure the quality complaint • Microbe analysis status
of the products • Microbes (record on production log)
• Discard product analysis of
above 2 days products
annually

Reheating 15(B) Reheating • Reheating • Check reheating • Kitchen • Baking • Every reheating • Ensure the • Calibration of • Microbe analysis status
temperature temperature temperature of personnel • Every serving packaging of the thermometer (record on production log)
= ≥ 76oC, • Centre the microwave meat pie is opened weekly • Customer complaint (record
centre temperature of • Check centre before reheating • Reviewing on customer satisfaction
temperature product temperature of • Ensure the meat records on document)
= ≥ 75oC product after pie is wrapped by regular basis • Batch temperature (record
reheating aluminium foils on production log)

56
 • Check the centre
temperature by
using digital food
cooking
thermometer
before serving

Table 4.11 Principle 7: Establishment of Record-Keeping Procedure

57
 4.13 HACCP PLAN: MEAT PIE

Ingredient/ CCP CL Monitoring Procedures Corrective Verification Process Records

Process No. Action
Step What How Where Who Frequency

Minced 1(B) Spoiled beef • Smelly beef • Perform a smell • Receiving • Receiving • Every • Return deliveries that do not • Microbes analysis of ingredients • Delivery temperature (record on
Beef = 0, • Delivery/storage test site personnel receiving meet quality standard during annually receiving log)
T = ≤ 6o C temperature • Check • Delivery • Bakery • Every receiving • Customer complaint • Return ingredients (record on
delivery/storage truck and manager before • Discard spoiled beef at bakery • Reviewing records on regular receiving log)
temperature storage opening as wastage basis • Microbe analysis status (record on
and closing • Preventive maintenance of production log)
storage to keep its efficiency • Storage temperature (record on
monthly bakery log)
• Customer complaint (record on
Eggs 2(B) Label • Smelly eggs • Perform a smell • Receiving • Receiving • Every • Return deliveries that do not customer satisfaction document)
expired date, • Delivery/storage test site personnel receiving meet quality standard during
Rotten egg temperature • Check • Delivery • Bakery • Every receiving
= 0, delivery/storage truck and manager before • Discard spoiled egg at bakery
T = ≤ 6o C temperature storage • Baking opening as wastage
• Check expiry • Kitchen personnel and closing • Preventive maintenance of
date • Every storage to keep its efficiency
• Perform a enclosing monthly
floating test process

Carrots 3(B) Unfreshened • Dark spot, soft, • Perform a sight • Receiving • Receiving • Every • Return deliveries that do not
carrot = 0, smelly carrots test, feel test, site personnel receiving meet quality standard during
T = ≤ 4 C • Delivery/storage
o
and smell test • Delivery • Bakery • Every receiving
temperature • Check truck and manager before • Discard unfreshened carrot at
delivery/storage storage • Cooking opening bakery as wastage
temperature • Kitchen personnel and closing • Preventive maintenance of
• Every storage to keep its efficiency
cooking monthly
process

Margarine 4(B) Label • Discoloration, • Check expiry • Receiving • Receiving • Every • Return deliveries that do not • Microbes analysis of ingredients • Delivery temperature (record on
expired date, mould, sour date site personnel receiving meet quality standard during annually receiving log)
T = ≤ 4o C smell, bad taste • Perform a sight • Delivery • Bakery • Every receiving • Customer complaint • Return ingredients (record on
• Delivery/storage test and smell truck and manager before • Discard spoiled margarine at • Reviewing records on regular receiving log)
temperature test storage • Bakery opening bakery as wastage basis • Microbe analysis status (record on
• Check • Kitchen personnel and closing • Preventive maintenance of production log)
delivery/storage • Every storage to keep its efficiency • Storage temperature (record on
temperature mixing monthly bakery log)
process • Customer complaint (record on
customer satisfaction document)

58
Irish 5(B) Wet spots = • Lesions on the • Perform a sight • Storage • Receiving • Every • Return deliveries that do not • Microbes analysis of ingredients • Return ingredients (record on
Potato 0 tubes as slightly test, feel test. personnel receiving meet quality standard during annually receiving log)
sunken, brown, • Bakery • Every receiving • Customer complaint • Microbes analysis status (record on
wet. manager before • Discard spoiled potato at • Reviewing records on regular production log)
opening bakery as wastage basis • Customer complaint (record on
and closing customer satisfaction document)

6(C) Solanine • Green colour in • Perform sight • Receiving • Receiving • Every • Discard the defective potato • Reviewing records on regular • Return ingredients (record on
level = tuber and test site personnel before • Make a report basis receiving log)
<0.555%, sprouted • Storage opening • Perform solanine level test • Solanine level status (record on
store at dark and closing analysis semi-annually production log)
room • Storage temperature (record on
storage bakery log)

Medium 7(B) Humidity = • Turn from • Perform a sight • Storage • Receiving • Every • Return deliveries that do not • Microbes analysis of ingredients • Microbe analysis status (record on
onion 65-70% brown to purple test, feel test. personnel before meet quality standard during annually production status)
with a halo of • Check humidity • Bakery opening receiving • Customer complaint • Storage humidity level (record on
yellow. level manager and closing • Discard spoiled onion at • Reviewing records on regular bakery log)
• bakery as wastage basis • Customer complaint (record on
customer satisfaction document)

Storage 8(B) Dry storage • Storage • Check storage • Storage • Bakery • Every • Check the temperature using • Calibration of thermometer • Storage temperature (record on
T = (25oC – temperature temperature manager before temperature calibrator weekly bakery log)
30oC), cold opening • Preventive maintenance of • Reviewing records on regular
storage T = and closing storage to keep its efficiency basis
≤ 4o C monthly
• Perform chemical washing on
heat exchanger annually

Cooking 9(B) Cooking • Cooking • Check cooking • Kitchen • Cooking • Every • Check the temperature of • Calibration of thermometer • Batch temperature (record on
temperature temperature temperature personnel cooking product using digital food weekly production log)
= ≥ 76oC process cooking thermometer and • Reviewing records on regular
meat food thermometer basis
• Ensure the accuracy of digital
food cooking thermometer and
meat food thermometer

Baking 10(B) Baking • Baking • Pre-heat baking • Kitchen • Baking • Every • Pre-heat oven before baking • Calibration of thermometer • Batch temperature (record on
temperature temperature temperature personnel baking • Check the temperature of oven weekly production log)
= ≥ 101oC • Check baking process using oven thermometer • Reviewing records on regular
temperature basis

Cooling 11(B) Cooling • Time • Check time • Kitchen • Baking • Every • Check the temperature of • Calibration of thermometer • Microbe analysis status (record on
period = 90 management period personnel cooling product using digital food weekly production log)
minutes • Surrounding • Ensure the process cooking thermometer • Reviewing records on regular • Batch temperature (record on
(< 2 hrs) conditions cleanliness • Check the time basis production log)

59
 surrounding • Microbe analysis of products
conditions, annually
SSOP

Packaging 12(B) Composition • Composition of • Ensure the • Kitchen • Packaging • Every • Check the composition of gas • Calibration of MAP machine • Batch production (records on
of gas; O2 = gas present. composition of personnel packaging by using modified atmosphere annually production log)
0%, CO2 = • Handling period the gas present • Bakery processes gas analyser • Reviewing on regular basis
50%, N2 = • Surrounding in the manager • Every day
50%, conditions packaging.
holding time • Check the time
= <10 and work faster
minutes, • Check
T= 25oC – surrounding
30oC temperature
• Ensure the
cleanliness
surrounding
conditions,
SSOP

Storage 13(B) T = ≤ 4o C • Storage • Check storage • Storage • Bakery • Every • Check the temperature using • Check the temperature using • Storage temperature (record on
temperature temperature manager before temperature calibrator temperature calibrator bakery log)
opening • Preventive maintenance of • Preventive maintenance of
and closing storage to keep its efficiency storage to keep its efficiency
monthly monthly
• Perform chemical washing on • Perform chemical washing on
heat exchanger annually heat exchanger annually

Display 14(B) T = (25oC – • Display case • Check display • Display • Bakery • Every • Reheat the products every • Calibration of display case • Date of batches displayed (records on
30oC) temperature case case manager before serving temperature production log)
Period: < 2 temperature • Cashier opening • Visual inspection on the • Reviewing records on regular • Display case temperature (record on
days and closing product displayed before basis bakery log)
serving • Customer complaint • Customer complaint (record on
• Ensure the quality of the • Microbes analysis of products customer satisfaction document)
products annually • Microbe analysis status (record on
• Discard product above 2 days production log)

Reheating 15(B) Reheating • Reheating • Check • Kitchen • Baking • Every • Ensure the packaging of the • Calibration of thermometer • Microbe analysis status (record on
temperature temperature reheating personnel reheating meat pie is opened before weekly production log)
= ≥ 76oC, • Centre temperature of • Every reheating • Reviewing records on regular • Customer complaint (record on
centre temperature of the microwave serving • Ensure the meat pie is basis customer satisfaction document)
temperature product • Check centre wrapped by aluminium foils • Batch temperature (record on
= ≥ 75oC temperature of • Check the centre temperature production log)
product after by using digital food cooking
reheating thermometer before serving

60
 SECTION 5

MEDIUM-SIZED BAKERY FLOOR PLAN

5.1 Floor Plan

Figure 5.1 Medium-sized Bakery Floor Plan

61
 5.2 Floor Plan References

TERMS DETAILS

Service Area - Buying and selling process happened in this area.

- The bakery products were placed either in display case or fridge
- Certain product will be reheated for serving to the customer that dine
in.
- The display case has a temperature around 25oC-30oC

Dining Area - Place for customer to dine in that provided with four dining tables
with 4 seated and communal table in the Service Area
Office Area - Place where all the documents be kept.
- Place where the dealing for bakery product bookings happened
- Place for customer service process
- Place where the dealing with suppliers happened
Kitchen Area - Place where the bakery was produced and processed
- Temperature of Kitchen Area is 25oC – 30oC
Receiving Site - Shipping and receiving process happened here
Dry Storage - Temperature is 25oC-30oC
- Walk-in storage
Cold Storage - Temperature is 0oC – 4oC
- Walk-in storage
Utility Room - Cleaning process for dining utensils, bakery utensils, plates, bowls
etc.
- Place for storing unused utensils etc.
- Chest freezer for temporary storage of bakery product.
- Garbage and wastage in the bin temporarily.
Janitor Room - Place for keeping janitor tools and equipment for SSOP.
Washroom - Sanitary room for worker.
Table 5.1 Medium-sized Bakery Floor Plan References

62
 REFERENCES

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