Issue No.

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

10. Hazard Control Plan (CCPs, OPRPs, Monitoring, Corrections and Corrective Actions, Validations)
Critical Monitoring
CCP/ Limit for each
Process Step Significant Hazard Control measure Correction Corrective Action Verification Records Validation doc.
OPRP preventive What How Frequency Who
measure
If the product
standards goes
below or above By checking the
Controlled As per the
Popped corns Production the critical limit Periodic quality quality of
process Quality checks as Corn Popping Companies
CCP Popping Un-popped corn from un-popped Every batch Manager/QC immediate quality checks & staff outcome product
adherence as per per SOP process record standard
ones Designate inspection to be training from any
standards acceptance limit
performed and deviations
approval as per
the standards
Oil stock bin cards
Contamination of Immediate quality
& physical
fresh oil with used checks and change By checking oil
inspection for oil As per FSSAI
oil, Chemical Immediately stop the entire lot of oil quality and
usage, Quality Periodic quality Production guidelines from
residue, increase Oil quality, the process if from the machines before
CCP Frying analysis of analysis & Every batch Manager/QC Frying Record Chapter 3 (3.1.8)
in FFA value, microbial activity deviation found equipment/machine. giving approval of
chemical process checks Designate and Schedule 4
Microbial activity and hold the lot CIP as per SOP new batch
properties, for Frying
from the presence before starting new production
Periodic Microbial
of Moisture/water batch of production
analysis
Extraneous matter Preventive
like metal pieces maintenance of
from machines machines and By checking final Adherence to
Immediately stop Immediate quality
(loosen nuts & quality checks, Baking Time & Periodic quality Production product quality FSSAI guidelines
Every batch/as the process if checks and PMS of
CCP Baking bolts), Increase of staff training, Temperature, checks, PMS of Manager/QC and machines Baking Record for food
per SOP deviation found equipment as per
microbial growth Quality checks for extraneous matter equipment Designate before approval preparation
and hold the lot SOP
due to baking of new batch under schedule 4
incompatible temperature and
temperature time
PMS of equipment
Passing test
to be done If metal
pieces of different
Quality checks for Hold the lot if contamination is
magnetic fields
metal materials not from equipment. If SECTION
(SS, Ferrous &
Metal fragments contaminants by Visual passed through, its field source - Metal Detector 555.425 - Foods -
Production Non- ferrous)
from RM, cross passing test Presence of metal examination/ metal detector. communicate to Records for Adulteration
CCP Metal Detector Every package Manager/QC through Metal
contamination & pieces through fragments passing through Clean & clear the sourcing team for test pieces & Involving Hard or
Designate Detector. Check
human errors Metal Detector as metal detector line immediately vendor for products Sharp Foreign
metal detector
per specified and identify the improvement. Re- Objects.
records for any
frequency source evaluate the
deviation
approved vendor
observed
list. Staff training
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

Incoming material
quality check as
per FSSAI
specification Checking for
based on List of approved approved Raw materials
Extraneous sampling plan. List materials from material Incoming
Raw & Packing testing by
matter of approved approved specification, Reject the entire RM/PM
Material receipt Supplier control on external As per FSSAI
(Other than RM), vendors, suppliers, vehicles by lot if not meets records,
OPRP from vendor, Every lot QC Designate RM, PM and laboratories on standards for
Pesticide residues, Approved vendor Cleanliness of; RM Visual/ inhouse standard Vehicle
Vehicle & QC incoming vehicles physical, chemical Raw Materials
Pest infestation, and cluster of & PM, condition quality requirement hygiene
Check & biological
high moisture product random of incoming inspection checklist
parameters
testing for vehicles
chemical &
microbial
parameters
(Once/Year)
PMS of heating
Hold the batch if By checking &
By inhouse kettle for proper Water quality
Addition of not achieved approving PMS
Water quality analysis temperature and analysis
water in pre- Quality analysis as Water quality & required machine work, cleaning & As per FSSAI
OPRP temperature, for water and Every lot QC Designate tests to be record, Kettle
mix kettle and per specification temperature & product water quality standards
quality & pH temperature of conducted to check temperature
heat temperature and before starting
kettle water quality, staff record
water quality new batch
awareness/training
Hold the batch if
deviation Quality checks shall
Quality inspection observed and be Vigilant to avoid Quality checks
By inhouse Production in- As per SOP/
Non coated & un- for finished conduct manual any deviation during during and after Manual sorting
OPRP Manual Sorting Popped corn online quality Every batch charge/QC accepting only
popped corn product as per cleaning of the sorting process, staff the process and Record
inspection Designate popped corns
specification product before awareness by maintain checklist
releasing to next training
process
Quality adherence
Periodic quality
as per As per FSSAI
Unseasoned Hold the process checks by
specification, standards in
Oil sprinkling Popcorn, Seasoning of Production in- if deviation Process approval as QC/production in-
Periodic quality By visual quality Seasoning Table no. 10, list
OPRP and seasoning Extraneous matter popcorn & Nacho Every batch charge/QC observed and re per standard recipe, charge for PMS &
analysis of oil, checks Record of food additives
application in seasoning, chips Designate process the step staff training CIP of machines,
Quality checks of for use in food
Rancidity of oil, as per SOP Seasoning & other
seasoning products
RM
material
Hold the process
Start the process
Quality checks as if desirable colling
only if the product
Cooling of per SOP, Control Line in- temperature not Product analysis Cooling of
Dust particles Cooling of By visual cooling happens as
OPRP Frymues on for process from Every batch charge /QC reached, as per Frymues As per SOP
Air monitoring Frymues inspection per SOP, PMS of
conveyers undesirable Designate immediately fix specification Record
machines, Staff
properties the maintenance
training
issues with the
 Issue No.: 01
HAZARD CONTROL Issue Date:
MANUAL Effective Date:
Rev. No.: 00
DJ BROTHERS Rev. Date:

machine
Cooking must
Stop the process if continue only if
Quality checks for
Microbial any temperature desired temperature As per FSSAI
Quality checks on temperature
growth by deviation achieves, staff guidelines from
Cooking process cooking By online Line in- issues and Cooking
OPRP deviating Cooking process Every batch observed during training on Schedule 4
in Nacho chips temperature & monitoring charge/QC product Record
cooking cooking, attend importance of Chapter 2 (2.4)
time as per SOP temperature after
temperature the maintenance cooking process & for cooking
cooking
issue immediately cooking
temperatures
As per FSSAI
Extraneous Hold the process PMS & CIP of
Visual (Food Product
matter other if desirable milling machines as per SOP
Preventive inspection/as per Standards &
than corn like is not obtained, & schedule, quality
maintenance of Monitoring as Line in- SOP by quality Milling Food Additives)
OPRP Milling metal pieces Corn milling Each batch PMS of machine clearance of
machines and per SOP charge/QC team or line in- Records Regulations,2011
from machines for proper milling machines before
quality checks charge in under II Food
(loosen nuts & and foreign starting the process,
production team Category
bolts) matter found Staff training
Description (6.0)
Foreign particles
in chips &
seasoning
CIP & regular Stop the process if
material,
maintenance of any physical,
Browning & PMS & CIP of
machines and chemical or As per FSSAI
discoloured machines, online Periodic quality
their parts, staff biological hazards standards in
slices, chemical visual inspection of inspection/as per
training, Quality mentioned Sorting & Table no. 10, list
Sorting of chips contamination chips as per SOP & SOP by quality
checks & control By visual Line in- observed, seasoning of food additives
OPRP & Seasoning during Potato chips Every batch schedule, online vi team production
on browning inspection charge/QC complete line application for use in food
application seasoning quality clearance of team & training
issues & other check is needed record products & act
preparation, machines before assessment of
chemical to run the as per SOP
Microbial starting the process, staff
contamination, production manual sorting
growth from Staff training
Periodic microbial without any
personnel
analysis deviation
contact &
facility
environment
Immediately stop
Primary As per FSSAI
Quality checks for the packing Quality checks as
Packaging; FG PM standard
contamination, Production in- process if any Proper check of each per SOP before Primary
Filling as per contamination, Quality checks as packaging &
OPRP nitrogen flushing, Packing process Every pack charge/QC deviation pack of the product releasing the Packaging
specification improper per SOP labelling
sealing & labelling Designate observed & act by line in-charge/QC product to next Record
and Nitrogen sealing regulations,
as per SOP accordingly as per process
flushing 2011 (2.4.5)
SOP