Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

1. Pre – Mixing

Biological Nil - - - - - -

- - - - - -
Chemical Nil

1.1 )Sewing needle 1) Can 1) Very Rare, it

( SS ) injure has a history
can be a possible source food occurrence Has potential to No Since Metal Detectors are Suppliers Annual audit
of hazard as in most handlers once in a year make anyone injured installed at the suppliers end ( Surprise Audit )
cases it is observed that hands or two. or affected but with to assure that not metal part is
flour industries has while 2) Very rare, may a very rare chance of contaminated in the flour
needle broken history product be a case in occurrence bags, further there is no any
1.1. (Sieving of with a frequent interval making, entire history historic evidence observed in
Flour) of minimum 6 times in a 2) can of product baking industries.
year. injure manufacturing.
consume
r mouth.

Physical
1) Can
1.2) Thread, Hair, Stone, injure 1) Very Rare, it Has potential to No Since we have sieve size of 180 Sieve Integrity via physical
Glass, Plastic. consume has a history make anyone injured micron that is 0.18 mm Inspection.
r mouth. occurrence or affected but with thickness per mesh so there is
once in a year a very rare chance of no chance for any foreign
or two. occurrence particle to pass through sieve

2.1. Hair, Dust Particles. 2.1. Can 2.1. Seldom happens in 2.1. Very low Strong GMP & PRP protocols Personal Hygiene &
Contaminate the General baking occurrence No follow-ups. Housekeeping strict follow ups
product physically surrounding but very rare probability with a with respect to availability of
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

and customer may in case of united kings low impact on food hair nets & beard caps as well
not be remained products due to strong safety. as with respect to surrounding
satisfied with the GMP protocols follow-ups. cleanliness.
product quality.
1.2. Sugar Biological Nil
Passing - - - - - -
Through
Magnetic Chemical Nil
Grill - - - - - -

Physical Metal Can injure 2)Very rare, may be a case Has potential to Since Magnetic Grill is in place Magnetic Grill
consumer mouth. in entire history of product make anyone injured No to eliminate chances of metal
manufacturing or affected but with or Iron Filling Contamination.
a very rare chance of
occurrence
1.3. Egg Biological Salmonella Can Cause Food 1 in every 20,000 eggs are Has potential to Since Fresh Eggs are being Proper Personal Hygiene
Breaking Poisoning such as contaminated with cause food poisoning No used for making recipe mix Practices, further baking steps
gastroenteritis - an Salmonella. unless properly and for Enrobing followed by to destroy Salmonella.
infection of the gut cooked. double baking steps at a
(intestines) which temperature around 180°c.
leads to diarrhea Since Salmonella can be
and being sick destroyed ( Killed ) at 150°F.
(vomiting)
Chemical Nil
Physical Egg Shells, Rubber Can Pose a negative Very rare as personals Very low occurrence No Since this process step is being
Bands image with respect deputed for task are probability with a carried out manually by highly Physical Inspection.
to product handling extremely skilled ones to low impact on food skilled personnel who have
quality while perform their jobs. safety. their job specific work
processing to the experience so there are very
consumer. rare likelihood of occurrence.
1.4. Preparation - - - - - -
of Color Biological Nil
Solution.
( Sun Set Color concentration Can damage liver & Very Rare since Recipe is f consumes above No Since Recipe is controlled with Obligation / strict follow up of
Yellow / Chemical beyond acceptable limit Kidneys functions, controlled with respect to than “acceptable respect to all ingredients “Master Recipe “that includes
Lime can cause hepatic all ingredients including daily intake “ including Additives. “Acceptable Daily Limit” for all
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

Yellow ) oxidative stress to Additives. ( ADI ) for 30 days or additives.

children under age more on a
of 12. In some cases continuous basis it
it is observed that it may harm / effect
affects body weight you adversely.
and growth of
children (as normal
food consumption
is reduced).

Physical Nil - - - - - -

Symptoms of Has potential impact

waterborne leading to Foodborne No Since Water is accepted on
Biological Coliforms, E Coli diseases may diseases if any of Neutral pH, So there is very
include Very common if control Coliform or E.coli rare likelihood of microbial Microbiological & Analytical
gastrointestinal measures are not in place. present in water contamination as they donot Testing
illness such as survive on higher Ph.
1.5. Water severe diarrhea,
Testing nausea, and
possibly jaundice as
well as associated
headaches and
fatigues.

Since water containing less

Chemical All heavy metals, Can be Very common if control Has potential impact No than 500 ppm / tds has very Organoleptic test ( Taste, Odor
pesticides and Carcinogenic if any measures are not in place. leading to cancer if less potential to be containing & Appearance) as well as TDS
radioactive substances of the heavy metal any of heavy metals heavy metals such as arsenic limit should be less than 500
like Arsenic, Lead present in water. and, further a comprehensive ppm / TDS is required for
etc is present in externl water testing outsourced water.( Hydrant
water. mechanism is in place to Water )
assure the all heavy metals are
either in operational limits or
not present.
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

Physical Sand Particles Can give unpleasant Very common if control High occurrence No Since Filters are installed on Sand Filters
mouth feel to the measures are not in place probability with a multiple locations to avoid
product. Customer low impact on food occurrence of sand particles to
may refuse product safety be incorporated in product.
on poor quality.
8. Mixing of ingredients
2.1. Addition of
materials in Biological Nil - - - - - -
mixer

If it is added
Chemical Grease accidentally with Since it was never Since Food Grade Since Food Grade Grease is Visual Inspection on a defined
product in more observed in any of United Grease is being used No being used at facility and there frequency by Maintenance
than acceptable King Facility that Grease is at facility and there are almost zero chances of Personnel to check whether
amount cross contaminated with are almost zero occurrence of product contact over lubrication occurs or not.
recommended by the product. chances of surface with the product and
FDA ( 10 PPM occurrence of grease.
Maximum ) some product contact
cases reported as surface with the
consumer product and grease.
complained “ Bad
Taste”, Temporary
Intestinal
Discomfort,”
Burning” in the
throat for upto
three hours “

Physical Thread, Hair, Stone, Can Contaminate 2.1. Seldom happens in Very low occurrence No Strong GMP & PRP protocols Sifting of all ingredients as well
Dust ,Glass, Plastic the product General baking probability with a follow-ups as Personal Hygiene &
physically and surrounding but very rare low impact on food Housekeeping strict follow ups
customer may not in case of united kings safety. with respect to availability of
be remained products due to strong hair nets & beard caps as well
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

satisfied with the GMP protocols follow-ups. as with respect to surrounding

product quality. cleanliness.

3. Filling ( Batter ) Biological Salmonella Can Cause Food 1 in every 20,000 eggs are Has potential to No Since Fresh Eggs are being Proper Personal Hygiene
Addition of Egg Poisoning such as contaminated with cause food poisoning used for making recipe mix Practices, further baking steps
Whisk gastroenteritis - an Salmonella. unless properly and for Enrobing followed by to destroy Salmonella.
infection of the gut cooked double baking steps at a
(intestines) which temperature around 180°c.
leads to diarrhea Since Salmonella can be
and being sick destroyed ( Killed ) at 150°F.
(vomiting)

Chemical Nil - - - - - -

Physical Egg shell Can Pose a negative Very rare as personals Very low occurrence No Since process step for egg Physical Inspection. Addition
image with respect deputed for task are probability with a breaking is being carried out of Egg whisk through egg shell
to product handling extremely skilled ones to low impact on food manually by highly skilled sieve,
quality while perform their jobs. safety personnel who have their job
processing to the specific work experience so
consumer there are very rare likelihood
of occurrence.

Can cause Nausea,

Biological Microbial Vomiting, Diarrhea May affect t anyone with a Has potential to Yes Strict Microbiological controls Baking at proper temperature
4. Baking contamination dehydration, weak immune system. cause food poisoning are in place to avoid / and time to avoid microbial
( Stage 01 ) ( Salmonella and / or Muscle Cramping unless properly eliminate Microbial growth periodic moisture
Streptococcus) leading to death in cooked Contamination Chances. check to control water activity
Elderly, Infants and and regular cleaning of the
debilitated People. oven
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

Chemical Grease If it is added Since it was never Since Food Grade No Since Food Grade Grease is Visual Inspection on a defined
accidentally with observed in any of United Grease is being used being used at facility and there frequency by Maintenance
product in more King Facility that Grease is at facility and there are almost zero chances of Personnel to check whether
than acceptable cross contaminated with are almost zero occurrence of product contact over lubrication occurs or not.
amount the product. chances of surface with the product and
recommended by occurrence of grease.
FDA ( 10 PPM product contact
Maximum ) some surface with the
cases reported as product and grease.
consumer
complained “ Bad
Taste”, Temporary
Intestinal
Discomfort,”
Burning” in the
throat for upto
three hours “

Physical Hair Can Contaminate Seldom happens in Very low occurrence Strong GMP & PRP protocols Personal Hygiene strict follow
the product General baking probability with a follow-ups ups with respect to availability
physically and surrounding but very rare low impact on food of hair nets & beard caps
customer may not in case of united kings safety
be remained products due to strong
satisfied with the GMP protocols follow-ups
product quality.

Biological Microbial Due to open Very rare to happen as the If retention time and Yes Since The maximum time and Product Cooling time
5. Cooling contamination, pest environmental maximum time and temperature are temperature for cooling or ( Between 20 – 25 minutes
and insect infestation prolong exposure of temperature for cooling or altered then desired product retention is never Maximum) at ambient
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

product may have product retention is never results will not come exceeded therefore it does not temperature ( 25°C -28°C ).
chances for exceeded therefore it does and there must be a have microbial growth
microbial not have microbial growth prone probability for evidences.
contamination such evidences. microbial If product is left for cooling for
yeast or mold reoccurrence to the 20 -25 minutes at ambient
growth. product. temperature (25°C - 28° C )it
never shows microbial growth
in product.

Chemical Nil - - - - - -

Physical
Nil - - - - - -

Yeast & Mold:

Since Yeast & Mold
do not harm Seldom happens in If sheeter and cutters
consumer directly General Orthodox baking are not properly Prompt Sanitation controls are Microbial testing for FG
Y on their health but surroundings but very rare sanitized prior to in place to eliminate microbial
it spoils the food in case of united kings operational use it growth Occurrence factors.
and not consider products due to strong may lead to
desirable for eating. GMP protocols follow-ups. occurance of
6. Sheeting & Biological Yeast and Mold, E Coli E. Coli : microbiological No
Cutting Bloody Diarrhea, contamination such
severe cramping, as Yest, Mold &
nausea and E.Coli Growth.
vomiting, in severe
case this may
progress to Life
Threatening
complications as
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

( HUS ) Where red

blood cells are
destroyed causing
kidney injury. This
can result in the
person requiring
intensive care,
Kidney Dialysis and
transfusions.

Chemical Cleaning chemical Can give an Very Rare as Residues Very low occurrence No Since Food Grade Cleaning pH and /or Litmus Test
residues unpleasant mouth usually removed after probability with a chemicals are being used
feel to the rinsing low impact on food which are comprised of low
consumer, or safety acid components
consumer may
refuse to poor
quality of product

Physical Hair & other Foreign Can Contaminate Seldom happens in Very low occurrence No Strong GMP & PRP protocols Personal Hygiene strict follow
matters the product General baking probability with a follow-ups ups with respect to availability
physically and surrounding but very rare low impact on food of hair nets & beard caps
customer may not in case of united kings safety
be remained products due to strong
satisfied with the GMP protocols follow-ups
product quality.

Can cause Nausea, Since Product is baked at

Microbial Vomiting, Diarrhea May affect t anyone with a Has potential to Yes around 200°C + Temperature Adequate Baking Time &
Biological contamination dehydration, weak immune system. cause food poisoning and at this temperature all Temperature.
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

7. Baking ( Final ) ( Salmonella and / or Muscle Cramping unless properly microbes such as salmonella
Streptococcus) leading to death in cooked and streptococcus are killed,
Elderly, Infants and hence Product is safe to be
debilitated People consumed by adequate baking
Practices.

If it is added
accidentally with Since it was never Since Food Grade Since Food Grade Grease is Visual Inspection on a defined
product in more observed in any of United Grease is being used No being used at facility and there frequency by Maintenance
than acceptable King Facility that Grease is at facility and there are almost zero chances of Personnel to check whether
Chemical Grease amount cross contaminated with are almost zero occurrence of product contact over lubrication occurs or not.
recommended by the product. chances of surface with the product and
FDA ( 10 PPM occurrence of grease.
Maximum ) some product contact
cases reported as surface with the
consumer product and grease.
complained “ Bad
Taste”, Temporary
Intestinal
Discomfort,”
Burning” in the
throat for upto
three hours “

Physical Hair Can Contaminate Seldom happens in Very low occurrence Strong GMP & PRP protocols Personal Hygiene strict follow
the product General baking probability with a follow-ups ups with respect to availability
physically and surrounding but very rare low impact on food of hair nets & beard caps
customer may not in case of united kings safety
be remained products due to strong
satisfied with the GMP protocols follow-ups
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

product quality.

8. Packing -
Biological Nil - - - - -

Chemical Nil - - - - - -

Physical Hair
Can Contaminate Seldom happens in Very low occurrence No Strong GMP & PRP protocols Personal Hygiene strict follow
the product General baking probability with a follow-ups ups with respect to availability
physically and surrounding but very rare low impact on food of hair nets & beard caps
customer may not in case of united kings safety
be remained products due to strong
satisfied with the GMP protocols follow-ups
product quality.

Biological Nil - - - - - -

9. Store
Chemical Cross contamination The harmful effects Seldom happens in Has Potential to No Since a prompt chemical Maintain hygienic storage
from Non-food range from minor General baking make someone control program is being condition.
chemicals gastric problems to surrounding but very rare seriously ill since non effectively in place at the
major health in case of united kings food chemicals can facility to avoid such
fatalities, Lack of products due to strong be insecticide, happenings.
Personal Control, GMP protocols follow-ups pesticides or any
Malnutrition etc. other chemical. Since
a prompt chemical
control program is
being effectively in
place at the facility
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

to avoid such
happenings.

Physical Hair Can Contaminate Seldom happens in Very low occurrence No Strong GMP & PRP protocols Personal Hygiene strict follow
the product General baking probability with a follow-ups ups with respect to availability
physically and surrounding but very rare low impact on food of hair nets & beard caps
customer may not in case of united kings safety
be remained products due to strong
satisfied with the GMP protocols follow-ups
product quality.

10. Transportation Biological Nil - - - - - -

( Loading &
Dispatch )
Chemical Grease If it is added Since it was never There are almost No There are almost zero chances Detailed Vehicle Inspection
accidentally with observed in any of United zero chances of of occurrence of product Prior to Loading & Unloading
product in more King Facility that Grease is occurrence of contact surface with the of Goods.
than acceptable cross contaminated with product contact product and grease.
amount the product. surface with the
recommended by product and grease.
FDA ( 10 PPM
Maximum ) some
cases reported as
consumer
complained “ Bad
Taste”, Temporary
Intestinal
Discomfort,”
Burning” in the
throat for upto
three hours “
 Hazard Identification & Analysis Worksheet (Process : Cake Rusk )

Significance of Hazard
Process Step Type of Cause of Hazard Justification of Decision Control Measure
Hazard

Severity of Hazard Likelihood of Hazard Risk Significant

Occurring Hazard
( Yes or No )

No Strong GMP & PRP protocols Personal Hygiene strict follow

Physical Packaging Can expose the Very Rare due to Good Very low occurrence follow-ups ups with respect to availability
Disintegration product to Manufacturing Practices probability with a of hair nets & beard caps
environment strict Follow-ups. low impact on food
safety