Issue No.

: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

HAZARD CONTROL MANUAL

DJ BROTHERS
Vasantha narsapura, Industrial Area,
rd
3 Phase, Kora Hobli, Tumkur Taluk & District,
Karnataka, India

Doc No: DJ/FS/02

Issue No: 01
Revision No: 00
Issue Date:

This document is the property of DJ Brothers. This document must not be passed on copied for other
companies or to outside persons without the written permission of Managing Director.

Approval

The signatures below certify that this Hazard Control manual has been reviewed and accepted, and
demonstrates that the signatories are aware of all the requirements contained herein and are
committed to ensuring their provision.

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Name Signature Position Date

Consultant - Food Safety
Prepared by Saleem Shaik

Reviewed by Head – QA

Approved by Managing Director

DISTRIBUTION OF HAZARD CONTROL MANUAL

Copy
Type Owner
Number
1 MASTER COPY Top Management
2 CONTROL COPY Certification body
3 CONTROL COPY Food safety & Quality team leader

AUTHENTICATION STATEMENT

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The Top Management states that this Hazard Control Manual is the original authenticated one. The
procedures and activities detailed in this manual are true and correct. State that this Manual follows
the code mentioned in HACCP Codex Alimentarius commission principles and ISO 22000. This
manual consists reference of SOP (Standard Operating Procedures), procedures, formats/records
and HACCP (Hazard Analysis Critical Control Point) Plans.

Issued by: Top Management

Issue Date:

COMPANY PROPRIETARY INFORMATION

The electronic version of this document is the latest revision. It is the responsibility of the individual
to ensure that any paper material is the current revision. The printed version of this Hazard Control
manual is uncontrolled, except when provided with a document reference number and revision in
the field below:

Document Reference Number Revision number Date

DJ/FS/01 00
Uncontrolled Copy Controlled Copy ✓

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Table of contents Page No.

S.No. Index Page No.
i Title Page 1-1
ii Approval & Distribution of Manual 2-2
iii Authentication statement 3-3
iv Table of contents 4-4
1 Purpose 5-5
2 Scope 5-6
3 Food safety team 7-7
4 Product Description 8-8
5 Intended Use 8-8
6 Process flow diagram 9 -10
7 Hazard Analysis and CCP determination Methodology 11 - 11
8 CCP and OPRP Categorization 12 - 15
9 Hazards Control Plan CCP & OPRP 16 - 16

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1 Purpose

The Hazard Control Manual specifies the steps to be taken in order to control hazards associated
with the Staples manufactured by eliminating or reducing them to acceptable levels so as to provide
safe product to the customer.

2 Scope

The manual covers all the processes required in building a Hazard Control Plan extends from
purchasing of raw materials from suppliers to dispatch of finished product.

Receiving, Processing and Dispatch of Pulses, Cereals, Flours, Dry fruits, Nuts and Whole Spices

TERMS AND DEFINITIONS

Acceptable level: level of food safety hazard not to be exceeded in the end product provided by the
organization.

Action criterion: measurable or observable specification for the monitoring of an OPRP

Conformity: fulfilment of a requirement.

Control measure: action or activity that is essential to prevent a significant food safety hazard, or
reduce it to an acceptable level.

Correction: action to eliminate a detected nonconformity.

Corrective action: action to eliminate the cause of a nonconformity and to prevent recurrence

Critical control point (CCP): step in the process at which control measure(s) is (are) applied to
prevent or reduce a significant food safety hazard to an acceptable level, and defined critical limits
and measurement enable the application of corrections.

Critical limit: measurable value which separates acceptability from unacceptability

End product: product that will undergo no further processing or transformation by the organization

Flow diagram: schematic and systematic presentation of the sequence and interactions of steps in
the process.

Food: substance (ingredients) whether processed, semi – processed or raw which is intended for
consumption, and includes drink, chewing gum and any substance which has been used in the
manufacture, preparation or treatment of “food” but does not include cosmetics or tobacco or
substances (ingredients) used only as drugs.

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Animal food: single or multiple product(s) whether processed, semi – processed or raw which is (are)
intended to be fed to non - food producing animals.

Food safety: assurance that food will not cause an adverse health effect for the consumer when it is
prepared and/or consumed in accordance with its intended use

Food safety hazard: biological, chemical or physical agent in food with the potential to cause an
adverse health effect

Measurement: process to determine a value

Monitoring: determining the status of a system, a process or an activity

Nonconformity: non – fulfilment of a requirement

Objective: result to be achieved

Operational Prerequisite Programme (OPRP): control measure or combination of control measures

applied to prevent or reduce a significant food safety hazard to an acceptable level and where action
criterion and measurement or observation enable effective control of the process and/or product

Prerequisite Programme (PRP): basic conditions and activities that are necessary within the
organization and throughout the food chain to maintain food safety

Significant food safety hazard: food safety hazard identified through the hazard assessment, which
needs to be controlled by control measures.

Validation: <food safety> obtaining evidence that a control measure or a combination of control
measures will be capable of effectively controlling the significant food safety hazard.

Verification: confirmation, through the provision of objective evidence, that specified requirements
have been fulfilled

3. Food Safety Team

S.No. Name Department Designation Food Safety Designation Contact Number
1 Quality Assurance Food Safety Team Leader
2 Production Food Safety Team Member

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3 Procurement Food Safety Team Member

5 Maintenance Food Safety Team Member
6 RM Stores Food Safety Team Member
7 Dispatches Food Safety Team Member
8 Accounts Food Safety Team Member
DJ Brothers has established a Food Safety Team and appointed Food Safety Team Members and a
Food Safety Team leader to manage development, implementation and continuous improvement of
the FSMS as follows:

3.1 Food Safety Team Responsibilities:

• Responsibility for participating, developing, maintaining and reviewing the food safety
program.
• Part of team to identify hazards that are expected to occur in the process steps. Establish and
validate the controls methods for CCP’s
• Participation in implementing monitoring systems for control of hazards, completes
workplace food safety records.
• Participation in implementing verification systems.
• Comply with safety and GMP issues.
• Can take customer complaints.
• Assist with auditing of the premises and food services.
• Part of management review team.
• Main person responsible for training staff on the shop floor.
• Can take and address customer complaints and corrective actions.
• Communicates to all relevant personnel food safety responsibilities and all information
essential to ensure the effective implantation and maintenance of all quality and food safety
systems. This includes - Responsibility for the communication to the management and
supervisory staff of the importance of meeting statutory, legal and customer requirements.
• Ensures product safety, quality and legal requirements are maintained.
• Ensure that products are produced/ packaged to customer specifications.
• Ensure goods received are within specification.
• Responsible for corrective action and the handling and disposition of non-conforming
product.
• Authority or implementation and completion of recall procedures. Recall Coordinator.
• Responsible for the development, training and safety of all food handling personnel.

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4. Product Description

Product Name Caramel coated popcorn, chocolate coated popcorn, savoury popcorn, Nacho
chips & Potato chips
General Product Specs As per FSSAI & DJ Brothers Product specifications
Primary packaging PET & Poly Food Grade Packing covers

Secondary packing Poly bags and Carton boxes

Storage Conditions
Shelf life
Labelling instruction
Ambient temperature
To be included
Name of the Food Product, Veg Logo, Nutritional Information (For the
Products having more the single ingredient), Manufactured by Address
& Manufacturer FSSAI License No, Marketed by Address & Marketer FSSAI
License No,
Net Quantity, Batch No, Manufactured date, MRP ₹ (Incl. of all taxes), Best
Before / Expiry date, Storage Conditions of the Product, Customer Grievance
contact details, Recycling logo, Barcode EAN Number, Brand Logo

5. Intended Use

Where it will be sold DJ Brothers Clients and Customers

Who will consume For Human consumption

How is product used Ready to eat snack products

Risk Low

Sensitive population N/A

Intended for High Risk NA

product

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6. Process Flow Diagram

1. Caramel Coated Popcorn Production Process Flow Chart

IN
OUT IN

Dispatch as per FIFO Potable water from IFL Receipt of Raw and Packing materials Back Suppliers

Reject
Accept OPRP Chemical, pH & sensory analysis OK
Vehicle and Quality Checks OPRP Vehicle and Quality Checks Rework
Not OK
Storage in Tank
Accept
QA Approval Form
Storage as per Requirement
Add water as per specification in pre-mix
Control Sample kettle and heat continuously
Accept Issue to Production as per FIFO
Finished Product Analysis Rework
Reject Add ingredients as per recipe to form Corn Sieving
syrup. Transfer syrup to kettle coater
Corn Feeding
Secondary Packing: Packing
q
of pouches in corrugated
boxes as per specification Add butter and mix
Not OK
CCP 1 Popping As per SOP

Add Vanilla powder &

Caramel colour mix Separator Un-popped Corn
Primary Packing: Finished product
filling as per specification, nitrogen
flushing, Laminate sealing & coding OPRP Add to it
Popped Corn & Syrup is mixed Popped Corn Wastage
in the Kettle for coating
Not OK
Act as per QA OPRP
Metal Detector Manual Transfer Coated popcorn to cooling
Sorting tunnel drum to separate cluster
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CCP 2
2. Savoury Popcorn Production Process Flow Chart
IN
OUT

Receipt of corn, oil seasoning

Dispatch as per FIFO & packaging materials Back Suppliers

Reject
Accept
OK
Vehicle and Quality Checks OPRP Vehicle and Quality Checks Rework
Not OK
Accept
QA Approval Form Storage as per Requirement
Accept
Finished Product Analysis Rework
Reject Issue to Production as per FIFO

Control Sample Corn Sieving

Corn Feeding
Secondary Packing:
q
Packing of pouches in
corrugated boxes as per Not OK
CCP 1 Popping As per SOP
specification

Not OK Separator Un-popped Corn

Act as per QA

Primary Packing: Finished product filling Oil sprinkling and seasoning

Popped Corn Wastage
Metal Detector as per specification, nitrogen flushing, application
Laminate sealing & coding OPRP
CCP 2
OPRP

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3. Chocolate Coated Popcorn Production Process Flow Chart

IN
OUT IN

Dispatch as per FIFO Potable water from IFL Receipt of Raw and Packing materials Back Suppliers

Reject
Accept OPRP Chemical, pH & sensory analysis OK
Vehicle and Quality Checks OPRP Vehicle and Quality Checks Rework
Not OK
Storage in Tank
Accept
QA Approval Form
Storage as per Requirement
Add water as per specification in pre-mix
Control Sample kettle and heat continuously
Accept Issue to Production as per FIFO
Finished Product Analysis Rework
Reject Add ingredients as per recipe to form Corn Sieving
syrup. Transfer syrup to kettle coater
Corn Feeding
Secondary Packing: Packing
q
of pouches in corrugated
boxes as per specification Add butter and mix
Not OK
CCP 1 Popping As per SOP

Add Cocoa powder &

Chocolate flour mix Separator Un-popped Corn
Primary Packing: Finished product
filling as per specification, nitrogen
flushing, Laminate sealing & coding OPRP Add to it
Popped Corn & Syrup is mixed Popped Corn Wastage
in the Kettle for coating
Not OK
Act as per QA OPRP
Metal Detector Manual Transfer Coated popcorn to cooling
Sorting tunnel drum to separate cluster
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CCP 2
4. Frymues Popcorn Production Process Flow Chart
IN
OUT

Receipt of oil, pellets, seasoning

Dispatch as per FIFO & packaging materials Back Suppliers

Reject
Accept
OK
Vehicle and Quality Checks OPRP Vehicle and Quality Checks Rework
Not OK
Accept
QA Approval Form
Storage as per Requirement
Accept
Finished Product Analysis Rework
Reject

Control Sample Issue to Production as per FIFO

Secondary Packing: Packing Feeding of pellets

of pouches in corrugated (Pasta, wheels & sticks)
boxes as per specification

Not OK Frying CCP 1

Act as per QA

Primary Packing: Finished product filling as Cooling on conveyer for 2 -3

per specification, nitrogen flushing, Laminate Seasoning Application OPRP
Metal Detector mins
sealing & coding
CCP 2
OPRP

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5. Nacho Chips Production Process Flow Chart

IN
Primary Packing: Finished product CCP 3 OPRP
filling as per specification, nitrogen
Metal Detector Oil spray & seasoning Receipt of Raw and Packing materials Back Suppliers
flushing, Laminate sealing & coding
application
Not OK Reject
OK
Act as per SOP OPRP Vehicle and Quality Checks Rework
Secondary Packing: Packing of Frying CCP 2 Not OK
Not OK Accept
pouches in corrugated boxes as
per specification Storage as per Requirement
Cooling on HTC conveyer

Issue to Production as per

CCP 1 Baking Act as per SOP FIFO
Finished Product Analysis Not OK

Control Sample In the kettle: add potable water,

Raw Nacho chips formation
corn & heat up to specified Store in Tank
Reject
as per requirement
QA Approval Form temperature & time with stirrer on
Rework
Accept Blending & Sheeting
Chemical, pH
Cooking is stopped at
OPRP & sensory OPRP
MASA Dough formation specified temperature
Vehicle and Quality Checks
Accept Add quench water
OPRP Milling Potable water
Corn Soaking
Dispatch as per FIFO from IFL

Secondary corn washing in Primary corn washing through

drum Hydra sieve to remove added lime
IN
OUT
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Soaked waste water

6. Potato Chips Production Process Flow Chart

IN

Primary Packing: Finished product

Secondary Packing: Packing of
filling as per specification, nitrogen Receipt of Raw and Packing materials Back Suppliers
pouches in corrugated boxes as
flushing, Laminate sealing & coding
per specification
Reject
Not OK Act as per OK
SOP OPRP Vehicle and Quality Checks Rework
Reject CCP 2 Metal Detector Not OK
Finished Product Analysis Rework Accept
Accept Storage as per Requirement
Control Sample
OPRP Seasoning application
Issue to Production as per
QA Approval Form FIFO

Potato Feeding
Fried Potato Chips
Vehicle and Quality Checks
De-stoning & washing Store in Tank
Accept
Potato skin &
Dispatch as per FIFO Peeling OPRP Chemical, pH
Browning & waste water OPRP
Sorting of chips & sensory
over fried chips
Waste water Sorting & washing
OUT Potable water
from IFL
Slicing OPRP

Act as per SOP Frying Washing & De-watering IN

Not OK with air blow
CCP 1
14 Water & slicing
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7. Step by step procedure

1. Caramel Coated Popcorn Step by step Process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Corn Popping
Step-6 Separator to sort popped & un-popped corn
Step-7 Add water in premix kettle and heat continuously
Step-8 Add ingredients as per recipe to form syrup & transfer syrup to other kettle for coating
Step-9 Add butter and mix
Step-10 Add Vanilla powder and Caramel colour & mix
Step-11 Mix Popped corn coming from Separator (from Step-7) and Syrup in the kettle for coating
Step-12 Transfer Coated Popcorn to colling tunnel drum to separate clusters
Step-13 Manual sorting
Step-14 Passing through Metal Detector
Step-15 Primary Packaging; FG Filling as per specification and Nitrogen flushing
Step-
Secondary Packaging; packing of pouches in corrugated boxes as per specification
16
Step-
Finished Product Analysis
17
Step-18 Quality Clearance for Finished Goods & Vehicles
Step-
Dispatch as per FIFO
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2. Savoury Popcorn Step by step Process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Popping
Step-6 Separator to sort popped & un-popped corn
Step-7 Popped corn
Step-8 Oil sprinkling and seasoning application to popped corn
Step-9 Primary Packaging; FG Filling as per specification and Nitrogen flushing
Step-10 Passing through Metal Detector
Step-11 Secondary Packaging; packing of pouches in corrugated boxes as per specification
Step-12 Finished Product Analysis
Step-13 Quality Clearance for Finished Goods & Vehicles
Step-14 Dispatch as per FIFO

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3. Chocolate popcorn step by step process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Popping
Step-6 Separator to sort popped & un-popped corn
Step-7 Add water in premix kettle and heat continuously
Step-8 Add ingredients as per recipe to form syrup & transfer syrup to other kettle for coating
Step-9 Add butter and mix
Step-10 Add Cocoa powder and Chocolate flavour & mix
Step-11 Mix Popped corn coming from Separator (from Step-7) and Syrup in the kettle for coating
Step-12 Transfer Coated Popcorn to colling tunnel drum to separate clusters
Step-13 Manual sorting
Step-14 Passing through Metal Detector
Step-15 Primary Packaging; FG Filling as per specification and Nitrogen flushing
Step-
Secondary Packaging; packing of pouches in corrugated boxes as per specification
16
Step-
Finished Product Analysis
17
Step-18 Quality Clearance for Finished Goods & Vehicles
Step-
Dispatch as per FIFO
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4. Frymues production Step by step process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Feeding of Pellets (Pasta, Wheels & Sticks)
Step-6 Frying
Step-7 Cooling on conveyer for 2-3 mins
Step-8 Application of Seasonings
Step-9 Primary Packaging; FG Filling as per specification and Nitrogen flushing
Step-10 Passing through Metal Detector
Step-11 Secondary Packaging; packing of pouches in corrugated boxes as per specification
Step-12 Finished Product Analysis
Step-13 Quality Clearance for Finished Goods & Vehicles
Step-14 Dispatch as per FIFO

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5. Nacho Chips Step by step process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Add potable water & corn and heat up to specified temperature & time
Step-6 Cooking is Stopped at specified temperature
Step-7 Corn soaking
Step-8 Primary corn washing through Hydra sieve to remove added lime
Step-9 Secondary corn washing in drum
Step-10 Milling
Step-11 MASA dough formation
Step-12 Blending & Sheeting
Step-13 Raw Nacho Chips formation as per requirement
Step-14 Baking
Step-15 Cooling on HTC conveyer
Step-
Frying
16
Step-
Oil spray and seasoning application
17
Step-18 Passing through Metal Detector
Step-
Primary Packaging; FG Filling as per specification and Nitrogen flushing
19
Step-20 Secondary Packaging; packing of pouches in corrugated boxes as per specification

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Step-21 Finished Product Analysis

Step-22 Quality Clearance for Finished Goods & Vehicles
Step-23 Dispatch as per FIFO

6. Potato Chips Step by step process

Steps Description
Step-1 Receipt of Raw & Packaging materials
Step-2 Vehicle & Quality Inspection
Step-3 Storage as per requirement (Ambient Storage)
Step-4 Issue to production as per FIFO
Step-5 Feeding of potatoes
Step-6 De-stoning and washing
Step-7 Peeling
Step-8 Sorting and washing
Step-9 Slicing
Step-10 Washing & de-watering with air blow
Step-11 Frying
Step-12 Sorting of chips to remove browning and over fried chips
Step-13 Seasoning Application
Step-14 Passing through Metal Detector
Step-15 Primary Packaging; FG Filling as per specification and Nitrogen flushing
Step-
Secondary Packaging; packing of pouches in corrugated boxes as per specification
16
Step-
Finished Product Analysis
17
Step-18 Quality Clearance for Finished Goods & Vehicles

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Step-
Dispatch as per FIFO
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8. Hazard Analysis and CCP Determination

The food safety team has followed the following methodology to conduct the HACCP
analysis:
• Identification of product process steps for the product clusters, based on the flow
diagram.
• For each process step:
➢ Identification of potential hazards associated with what process step.
➢ Classification of hazard based on type (whether physical, biological or chemical)
➢ A description of the hazard
Likelihood of Very Low/
Occurrence Insignificant Low/Minor Moderate/Serious Major/Tragic High/Catastrophic
Rare 1 2 3 4 5
Low/unlikely 2 4 6 8 10
Moderate/Possible 2 6 9 12 15
High/Likely 4 8 12 16 20
Almost certain 5 10 15 20 25
➢ The likely occurrence of the identified hazard, evaluated quantitatively, in
terms of high, medium or low likelihood of occurrence, as follows:

The risk rating, in quantitative terms (arrived at by multiplying the likelihood of occurrence
with the severity of impact), and the classification of the identified hazard into significant
or non-significant category based on the risk rating factor.
Low Medium High
Risk Rating
1–6 7 - 12 13 - 25
Control measure PRP OPRP CCP

Q1. Could a control
measure(s) be used by the
operator at any process step?
If No = not a CCP +
identification on how this
hazard will be controlled and
after the process + proceed to
next identified hazard
If Yes= description + next
question
8.1 Methodology used for determination of CCP
Q2. Is it likely that Q3. Is this process Q4. Will a subsequent step
contamination with the specifically designed to eliminate the identified hazard or
identified hazard could eliminate/ reduce the reduces its likely occurrence to
occur in excess of the likely occurrence of the an acceptable level?
acceptable level or could identified hazard to an
increase to an acceptable level? If No= CCP
unacceptable level?
If No= next question If Yes = not a CCP+ identify
If No = not a CCP +
subsequent step + proceed to
proceed to the next If Yes= CCP + go to last next identified hazard
identified hazard
column
If Yes = next question

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9. CCP-OPRP Categorization
1. Caramel Coated Popcorn Process
Hazard Identification Hazard Assessment
Step Likelihood of Type of
Process Step Hazard Acceptable Level Severity Risk Control Measures
No. Category occurrence Hazard
(P, C, M) (B) (A x B)
(A)
Incoming material quality check as per FSS
Extraneous matter
Raw & Packing Physical As per specification 2 4 8 specification based on sampling plan. List
(Other than RM)
Material receipt approved vendors
1&2 from vendor, As per FSSAI OPRP -1 Approved vendor and cluster of product rand
Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Physical Nil N/A N/A N/A N/A N/A

Issue to
4 production as per Chemical Nil N/A N/A N/A N/A N/A
FIFO
Microbial Nil N/A N/A N/A N/A N/A

Physical Un-popped corns Absent 4 5 20 Controlled process adherence as per standa

5 Corn Popping Chemical Nil N/A N/A N/A N/A CCP-1 N/A

Microbial Nil N/A N/A N/A N/A N/A

N/A
Physical Nil N/A N/A N/A N/A
N/A
6 Separator Chemical Nil N/A N/A N/A N/A
N/A
Microbial Nil N/A N/A N/A N/A
N/A
7 Add water in Physical Nil N/A N/A N/A N/A OPRP- 2

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Water temperature & Quality analysis as per specification

Chemical As per specification 2 5 10
premix kettle & pH
heat it N/A
Microbial Nil N/A N/A N/A N/A
N/A
Physical Nil N/A N/A N/A N/A
Add ingredients
N/A
8&9 to form syrup, Chemical Nil N/A N/A N/A N/A
add butter & mix
N/A
Microbial Nil N/A N/A N/A N/A
Controlled adherence on specification by
Physical Colour & odour As per specification 2 3 6
inhouse quality analysis
Add Vanilla
Contains volatile Conduct Detailed tests from external labora
10 powder & Chemical Absent 3 2 6 PRP-2
flavouring chemicals (Yearly once)
Caramel colour
Microbial Nil N/A N/A N/A N/A N/A
Mix popped corn
& syrup in the Physical Nil N/A N/A N/A N/A N/A
Kettle and
11 &
transfer coated Chemical Nil N/A N/A N/A N/A N/A
12
popcorn to
cooling drum to
Microbial Nil N/A N/A N/A N/A N/A
separate clusters
Properly coated
Non coated & un- Quality inspection for finished product as p
Physical popped corns without 3 4 12
popped corn specification
any clusters
13 Manual Sorting OPRP-3
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

Metal fragments from
Quality checks for metal contaminants by pa
RM, cross
Physical Absent 4 5 20 test pieces through Metal Detector as pe
contamination &
specified frequency
Pass through human errors
14 CCP-2
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

Primary PM contamination, Quality checks for contamination, nitroge
15 Physical Absent 2 4 8 OPRP-4
Packaging; FG improper sealing flushing, sealing & labelling as per SOP

24
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Filling as per Chemical Nil N/A N/A N/A N/A N/A

specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A
External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
16, Finished Product
loading process.
17, 18 Analysis, Quality PRP-3
Contamination due to
& 19 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

25
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

2. Savoury Popcorn process

Hazard Identification Hazard Assessment

Step Likelihood of Type of
Process Step Hazard Acceptable Level Severity Risk Control Measures
No. Category occurrence Hazard
(P, C, M) (B) (A x B)
(A)
Incoming material quality check as per HIPL
Extraneous matter
Raw & Packing Physical As per specification 2 4 8 FSSAI specification based on sampling plan.
(Other than RM)
Material receipt of approved vendors
1&2 from vendor, As per FSSAI OPRP -1 Approved vendor and cluster of product rand
Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Physical Nil N/A N/A N/A N/A N/A

Issue to
4 production as per Chemical Nil N/A N/A N/A N/A N/A
FIFO
Microbial Nil N/A N/A N/A N/A N/A

Physical Un-popped corns Absent 4 5 20 Controlled process adherence as per standa

5 Corn Popping Chemical Nil N/A N/A N/A N/A CCP-1 N/A

Microbial Nil N/A N/A N/A N/A N/A

N/A
Physical Nil N/A N/A N/A N/A
Separator & N/A
6&7 Chemical Nil N/A N/A N/A N/A
Popped Corn
N/A
Microbial Nil N/A N/A N/A N/A

8 Oil sprinkling & Physical Unseasoned Popcorn As per specification 3 3 9 OPRP- 2 Quality adherence as per specification

26
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

seasoning Chemical Nil Nil N/A N/A N/A N/A

application to
N/A
popped corn Microbial Nil N/A N/A N/A N/A
PM contamination, Quality checks for contamination, nitroge
Primary Physical Absent 2 4 8
improper sealing flushing, sealing & labelling as per SOP
Packaging; FG
9 Filling as per Chemical Nil N/A N/A N/A N/A OPRP-3 N/A
specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A
Metal fragments from
Quality checks for metal contaminants by pa
RM, cross
Physical Absent 4 5 20 test pieces through Metal Detector as pe
contamination &
specified frequency
Pass through human errors
10 CCP-2
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
11,12, Finished Product
loading process.
13 & Analysis, Quality PRP-2
Contamination due to
14 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

27
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

3. Chocolate Popcorn Process

Hazard Identification Hazard Assessment

Step Likelihood of Type of
Process Step Hazard Acceptable Level Severity Risk Control Measures
No. Category occurrence Hazard
(P, C, M) (B) (A x B)
(A)
Incoming material quality check as per HIPL
Extraneous matter
Raw & Packing Physical As per specification 2 4 8 FSSAI specification based on sampling plan.
(Other than RM)
Material receipt of approved vendors
1&2 from vendor, As per FSSAI OPRP -1 Approved vendor and cluster of product rand
Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Physical Nil N/A N/A N/A N/A N/A

Issue to
4 production as per Chemical Nil N/A N/A N/A N/A N/A
FIFO
Microbial Nil N/A N/A N/A N/A N/A

Physical Un-popped corns Absent 4 5 20 Controlled process adherence as per standa

5 Corn Popping Chemical Nil N/A N/A N/A N/A CCP-1 N/A

Microbial Nil N/A N/A N/A N/A N/A

N/A
Physical Nil N/A N/A N/A N/A
N/A
6 Separator Chemical Nil N/A N/A N/A N/A
N/A
Microbial Nil N/A N/A N/A N/A
N/A
7 Add water in Physical Nil N/A N/A N/A N/A OPRP- 2

28
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Water temperature & Quality analysis as per specification

Chemical As per specification 2 5 10
premix kettle & pH
heat it N/A
Microbial Nil N/A N/A N/A N/A
N/A
Physical Nil N/A N/A N/A N/A
Add ingredients
N/A
8&9 to form syrup, Chemical Nil N/A N/A N/A N/A
add butter & mix
N/A
Microbial Nil N/A N/A N/A N/A
Controlled adherence on specification by
Physical Colour & odour As per specification 3 2 6
inhouse quality analysis
Add Cocoa
Contains volatile Conduct Detailed tests from external labora
10 powder & Chemical Absent 2 3 6 PRP-2
flavouring chemicals (Yearly once)
Chocolate flavour
Microbial Nil N/A N/A N/A N/A N/A
Mix popped corn
& syrup in the Physical Nil N/A N/A N/A N/A N/A
Kettle and
11 &
transfer coated Chemical Nil N/A N/A N/A N/A N/A
12
popcorn to
cooling drum to
Microbial Nil N/A N/A N/A N/A N/A
separate clusters
Properly coated
Non coated & un- Quality inspection for finished product as p
Physical popped corns without 3 4 12
popped corn specification
any clusters
13 Manual Sorting OPRP-3
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

Metal fragments from
Quality checks for metal contaminants by pa
RM, cross
Physical Absent 4 5 20 test pieces through Metal Detector as pe
contamination &
specified frequency
Pass through human errors
14 CCP-2
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

Primary PM contamination, Quality checks for contamination, nitroge
15 Physical Absent 2 4 8 OPRP-4
Packaging; FG improper sealing flushing, sealing & labelling as per SOP

29
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Filling as per Chemical Nil N/A N/A N/A N/A N/A

specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A
External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
16, Finished Product
loading process.
17, 18 Analysis, Quality PRP-3
Contamination due to
& 19 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

4. Frymues Process

30
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Hazard Identification Hazard Assessment

Step Likelihood of Type of
Process Step Hazard Acceptable Level Severity Risk Control Measures
No. Category occurrence Hazard
(P, C, M) (B) (A x B)
(A)
Incoming material quality check as per HIPL
Extraneous matter
Raw & Packing Physical As per specification 2 4 8 FSSAI specification based on sampling plan.
(Other than RM)
Material receipt of approved vendors
1&2 from vendor, As per FSSAI OPRP -1 Approved vendor and cluster of product rand
Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Physical Nil N/A N/A N/A N/A N/A

Issue to
production as per
Chemical Nil N/A N/A N/A N/A N/A
4&5 FIFO & Feeding of
Pellets (Pasta,
Wheels & Sticks) Microbial Nil N/A N/A N/A N/A N/A

Contamination of Oil stock bin cards & physical inspection for

Physical As per specification 6 4 24
fresh oil with used oil usage

Chemical residue, As per FSSAI standard

6 Frying Chemical 4 5 20 CCP-1 Quality analysis of chemical properties
increase in FFA value Compliance
Microbial activity
Microbial from the presence of Absent 4 4 16 Periodic Microbial analysis
Moisture/water
Cooling on Physical Dust particles Absent N/A N/A N/A N/A
7 conveyer for 2-3 OPRP- 2
mins Chemical Nil N/A 4 3 12 Quality checks as per SOP

31
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Microbial Air monitoring As per specification 2 5 10 Control for process from undesirable proper

Physical Nil N/A N/A N/A N/A N/A

Application of
8 Chemical Nil N/A N/A N/A N/A N/A
seasoning
Microbial Nil N/A N/A N/A N/A N/A
PM contamination, Quality checks for contamination, nitroge
Primary Physical Absent 2 4 8
improper sealing flushing, sealing & labelling as per SOP
Packaging; FG
9 Filling as per Chemical Nil N/A N/A N/A N/A OPRP-3 N/A
specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A
Metal fragments from
Quality checks for metal contaminants by pa
RM, cross
Physical Absent 4 5 20 test pieces through Metal Detector as pe
contamination &
specified frequency
Pass through human errors
10 CCP-2
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
11,12, Finished Product
loading process.
13 & Analysis, Quality PRP-2
Contamination due to
14 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

5. Nacho Chips Process

Step Process Step Hazard Identification Acceptable Level Hazard Assessment Type of Control Measures
No. Category Hazard Likelihood of Severity Risk Hazard
(P, C, M) occurrence (B) (A x B)

32
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

(A)
Incoming material quality check as per HIPL
Extraneous matter
Raw & Packing Physical As per specification 2 4 8 FSSAI specification based on sampling plan.
(Other than RM)
Material receipt of approved vendors
1&2 from vendor, As per FSSAI OPRP -1 Approved vendor and cluster of product rand
Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Physical Nil N/A N/A N/A N/A N/A

Issue to
4 production as per Chemical Nil N/A N/A N/A N/A N/A
FIFO
Microbial Nil N/A N/A N/A N/A N/A
Add potable
Physical
water & corn and
Impure & cross
heat up to Chemical Quality checks for water quality, pH and sen
5 contamination of As per specification 4 3 12 OPRP-2
specified analysis
water
temperature &
Microbial
time
N/A
Physical Nil N/A N/A N/A N/A
Cooking is
N/A
stopped at Chemical Nil N/A N/A N/A N/A
6 OPRP-3
specified
Microbial growth by Quality checks on cooking temperature & tim
temperature
Microbial deviating cooking Absent 4 3 12 per SOP
temperature
Corn soaking, Physical
Cross contamination
7, 8 & Primary and Chemical Use of separate soaking and washing
of fresh water with As per SOP 3 2 6 PRP -2
9 Secondary Corn tools/drums with proper cleaning measure
Microbial used/waste water
washing process
Preventive maintenance of machines and qu
10 Milling Physical Extraneous matter As per specification 3 4 12 OPRP-4

33
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

other than corn like checks

metal pieces from
machines (loosen
nuts & bolts)
Chemical Nil N/A N/A N/A N/A N/A
Microbial NIl N/A N/A N/A N/A N/A
MASA dough N/A
Physical Nil N/A N/A N/A N/A
formation,
11,12 Blending & N/A
Chemical Nil N/A N/A N/A N/A
& 13 Sheeting,
Raw Nacho Chips N/A
Microbial Nil N/A N/A N/A N/A
formation
Extraneous matter
like metal pieces from Preventive maintenance of machines and qu
Physical Absent N/A N/A N/A
machines (loosen checks, staff training
nuts & bolts)
14 Baking Chemical Nil N/A N/A N/A N/A CCP-1 N/A
Increase of microbial
growth due to
Microbial Absent N/A N/A N/A Quality checks for baking temperature and ti
incompatible
temperature
Physical Nil N/A N/A N/A N/A N/A
Cooling on HTC Chemical Nil N/A N/A N/A N/A N/A
15
conveyer
Microbial Nil N/A N/A N/A N/A N/A
Contamination of Oil stock bin cards & physical inspection for
Physical As per specification 6 4 24
fresh oil with used oil usage
Chemical residue, As per FSSAI standard
Chemical 4 5 20 Quality analysis of chemical properties
16 Frying increase in FFA value Compliance CCP-2
Microbial activity
Microbial from the presence of Absent 4 4 16 Periodic Microbial analysis
Moisture/water
Extraneous matter in
Physical Absent 4 3 12 Quality checks of seasoning material
seasoning
Oil spray &
17 Seasoning Chemical Rancidity of oil Absent 2 5 10 OPRP-5 Periodic quality analysis of oil
application
Microbial Nil N/A N/A N/A N/A N/A

18 Pass through Physical Metal fragments from Absent 4 5 20 CCP-3 Quality checks for metal contaminants by pa

34
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

RM, cross
test pieces through Metal Detector as pe
contamination &
specified frequency
human errors
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

PM contamination, Quality checks for contamination, nitroge
Primary Physical Absent 2 4 8
improper sealing flushing, sealing & labelling as per SOP
Packaging; FG
19 Filling as per Chemical Nil N/A N/A N/A N/A OPRP-4 N/A
specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A
External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
20,21, Finished Product
loading process.
22 & Analysis, Quality PRP-3
Contamination due to
23 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

6. Potato Chips Process

Hazard Identification Hazard Assessment
Step Likelihood of Type of
Process Step Hazard Acceptable Level Severity Risk Control Measures
No. Category occurrence Hazard
(P, C, M) (B) (A x B)
(A)
Raw & Packing Incoming material quality check as per HIPL
Extraneous matter
1&2 Material receipt Physical As per specification 2 4 8 OPRP -1 FSSAI specification based on sampling plan.
(Other than RM)
from vendor, of approved vendors

35
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

As per FSSAI Approved vendor and cluster of product rand

Chemical Pesticide residues 2 4 8
Vehicle & QC Compliance testing (Once/Year)
Check Pest infestation, high As per FSSAI Approved vendors and random testing for M
Microbial 2 4 8
moisture Compliance parameters
Prerequisites in place to control the hazar
Extraneous matter
Physical Absent 1 2 2 includes; Hygiene checks, glass policy, sta
(Other than RM)
training programs
RM Storage
3 Chemical Pesticide residues Absent 1 2 2 PRP -1 Controlled Storage & pre-requisite adheren
(Ambient Storage)

Microbial Fungal infection Absent 1 5 5 Controlled Storage & pre-requisite adheren

Issue to Physical Nil N/A N/A N/A N/A N/A

4 production as per Chemical Nil N/A N/A N/A N/A N/A
FIFO Microbial Nil N/A N/A N/A N/A N/A
Heavy metals from
Absent & as per
Physical raw water & stone 3 4 12 Regular checks, training & maintenance
Feeding of specification
fragments in potatoes
Potatoes, de-
5&6 Glycoalkaloids OPRP-2
stoning and Chemical Absent 4 3 12 Regular Quality inspections
formation in potato
washing
Microbial growth
Microbial Absent 3 3 9 Control & regular checks of raw water
from raw water
Spoiled potatoes,
Control & checks on extraneous matter & spo
Physical mud & stone particles Absent 2 3 6
potatoes. Regular staff training
due to poor operation
Peeling, sorting & Residue of cleaning Water Quality & pH analysis, clean in place (
7&8 Chemical As per specification 3 2 6 PRP-2
washing agents of equipment/machines
Cross contamination/
Microbial microbial growth Absent 2 3 6 Quality checks as per SOP
from dirty water
Physical Nil N/A N/A N/A N/A N/A

9 Slicing Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

10 Washing & de- Physical Attachment of foreign Absent 3 4 12 PRP-3 CIP & regular maintenance of machines and
watering with air particles on high- parts, staff training
blow speed blade

36
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Chemical Nil N/A N/A N/A N/A N/A

Microbial growth
CIP & regular maintenance of machines and
Microbial from air blower & Absent 3 4 12
parts, staff training
speed belt
Contamination of
Physical As per specification 6 4 24 Removal of burnt oil as per SOP, staff train
fresh oil with used oil
Chemical residue, As per FSSAI standard Conduct Detailed tests for FFA from extern
11 Frying Chemical 4 5 20 CCP-1
increase in FFA value Compliance laboratory
Microbial activity
Microbial from the presence of Absent 4 4 16 Periodic Microbial analysis
Moisture/water
Foreign particles in
CIP & regular maintenance of machines and
Physical chips & seasoning Absent 3 4 12
parts, staff training
material
Browning &
discoloured slices,
Sorting of chips & chemical Absent or as per Quality checks & control on browning issue
12 & Chemical 3 4 12
Seasoning contamination during specification OPRP-4 other chemical contamination
13
application seasoning
preparation
Microbial growth
from personnel
Microbial Absent 4 3 12 Periodic microbial analysis
contact & facility
environment
Metal fragments from
Quality checks for metal contaminants by pa
RM, cross
Physical Absent 4 5 20 test pieces through Metal Detector as pe
contamination &
specified frequency
Pass through human errors
14 CCP-2
Metal Detector
Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

PM contamination, Quality checks for contamination, nitroge
Primary Physical Absent 2 4 8
improper sealing flushing, sealing & labelling as per SOP
Packaging; FG
15 Filling as per Chemical Nil N/A N/A N/A N/A OPRP-4 N/A
specification and
Nitrogen flushing Microbial Nil N/A N/A N/A N/A N/A

37
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

External
contamination like
rain water, Bird
Secondary
droppings, rodents & Quality checks and clearance for Secondar
Packaging, Physical Absent 2 3 6
flying insects during packing, FG & vehicles at the point of dispa
16,17, Finished Product
loading process.
18 & Analysis, Quality PRP-4
Contamination due to
19 Clearance for FG
dirty Vehicle
& Vehicles,
Dispatch Chemical Nil N/A N/A N/A N/A N/A

Microbial Nil N/A N/A N/A N/A N/A

38