Tea Estate SOP

FOOD SAFETY MANUAL
M/S DHUNSERI TEA & INDUSTRIES LIMITED
DILLI TEA ESTATE

PO- PARBATPUR, DIBRUGARH, ASSAM
DHUNSERI TEA & INDUSTRIES Doc No. : DLI-FSM-001

LIMITED FOOD SAFETY MANUAL Issue No. 1
Page No. : 1
DILLI TEA ESTATE LIST OF CONTENTS Rev. No. : 0
ASSAM
Clause No. Titles Document No. Page Nos.
- List of Contents DLI-FSM-001 1 to 2

- Introduction DLI-FSM-002 3
1 Scope DLI-FSM-003 4
2 Normative References DLI-FSM-004 5
- List of Abbreviations DLI-FSM-005 6
- List of Amendments DLI-FSM-006 7
3 Terms and Definitions DLI-FSM-007 8 to 10
4 Food Safety Management System DLI-FSM-008

4.1 General Requirements " 11
4.2 Documentation Requirements " 12 to 15
5 Management Responsibility DLI-FSM-009

5.1 Management Commitment " 16
5.2 Food Safety Policy & Measurable Objectives " 16 & 17
5.3 Food Safety Management System Planning " 17
5.4 Responsibility and Authority " 18 to 19
5.5 Food Safety team Leader " 20
5.6 Communication " 21
5.7 Emergency Preparedness and Response " 22
5.8 Management Review " 23
6 Resource Management DLI-FSM-010

6.1 Provision of Resources - Organization Chart " 24
6.2 Human Resources " 25 to 26
6.3 Infrastructure " 27
6.4 Work Environment " 27
7 Planning and Realization of Safe Products DLI-FSM-011

7.1 General " 28
7.2 Pre-requisite Programmes " 28 & 29
7.3 Preliminary steps to enable hazard analysis DLI-FSM-012 30
Approved By : Released By -
Assistant Manager-Factory Senior Manager
Date : March 2009
Doc No. : NHR-FSM-001

DHUNSERI TEA&INDUSTRIES FOOD SAFETY MANUAL Issue No. 1
LIMITED Page No. : 2
DILLI TEA ESTATE LIST OF CONTENTS Rev. No. : 0
ASSAM
Clause No. Titles Document No. Page Nos.
7.3.2 Food Safety Team DLI-FSM-012 30

7.3.3 Product Characteristics DLI-FSM-013 31 to 33
7.3.4 Intended Use DLI-FSM-014 34
7.3.5 Flow Diagrams, Process Steps and DLI-FSM-015 35 to 41
Control Measures
7.4 Hazard Analysis DLI-FSM-016 42 to 54
7.4.1 General "
7.4.2 Hazard Identification and Determination of "
Acceptable levels
7.4.3 Hazard Assessment "
7.4.4 Selection and assessment of Control DLI-FSM-017 55 to 62
measures
7.5 Establishing the Operational prerequisite DLI-FSM-018 63
programmes
7.6 Establishing the HACCP Plan
7.6.1 Food Safety Plan DLI-FSM-019 64 to 67
7.6.2 Identificaion of Critical Control Points "
7.6.3 Determination of Critical Limits for CCP's DLI-FSM-020 68 & 69
7.6.4 System for the monitoring of CCP's DLI-FSM-021 70 to 72
7.6.5 Actions when monitoring results exceed DLI-FSM-022 73 & 74
Critical limits
7.7 Updating of preliminary information and
Documents specifying the PRP's and the " 75
HACCP Plan
7.8 Verification Planning DLI-FSM-023 76
7.9 Traceability System DLI-FSM-024 77 & 78
7.10 Control of Non-Conformity DLI-FSM-025 79
7.10.2 Corrective Action " 80
7.10.3 Handling Potentially unsafe Products DLI-FSM-026 81
7.10.4 Withdrawals DLI-FSM-027 82 & 83
8 Validation,Verification and improvement of
the Food Safety Management System
8.1 General DLI-FSM-028 84
8.2 Validation of Control measure combinations "
8.3 Control of Monitoring and Measuring " 85
8.4 Food safety Management system Verification DLI-FSM-029 86 & 87
8.5 Improvement DLI-FSM-030 88
Date : March 2009
AMALGAMATED Doc No. : NHR-FSM-002

PLANTATIONS FOOD SAFETY MANUAL Issue No. 1
PRIVATE LIMITED Page No. : 3
NAHORANI TEA ESTATE INTRODUCTION Rev. No. : 0
SONITPUR, ASSAM
The e sta te w as name d as Na hora ni Tea Estate as there w ere a nu mber of Nah or trees in the su rroun din gs. Th is
estate originally belonged to Borellie Tea Co. which was subsequently taken over by Anglo Amercian Direct Trading
C o. L td .d urin g 187 6 as pe r the l and re cords a vail abl e. The reafter, Ja mes Fi nla y to ok over the estate a nd in 1 976 i t
became Tata Finlay. Again in 1983 it became Tata Tea Limited and remained so till April 2008.
From May 2008, the Company was transferred to a new Tata Enterprise, Amalgamated Plantations Private Limited.
This estate is known for its good quality Orthodox and CTC tea.
The estate is located next to Rangapara Town in Sonitpur District on the northern bank of the river Brahmaputra. The
district headquarters, Tezpur is situated 33 km away. The nearest railway station is situated at Rangapara which is
only 3 km from the estate. The airport (Tezpur) is also situated 23 km away from the estate. The estate is well
connected by road, rail & air.
Presently the estate's total grant area is 1115 hectares. Out of this, 705.68 hectares is under tea cultivation. The
average production is 13.00 lac kg of Orthodox & CTC tea.
The e mplo yee de ta ils are a s fo llo ws:

1. Total Garden Labour - 1401
2. Staff - 34
3. Sub-Staff - 49
4. Artisan Staff - 22
5-In Factory-50
The estate has a total residential population of 8069 including depandants & non-workers.
Please give the respective gardens detais on the top
Date : March 2009

NAHORANI TEA ESTATE 1. SCOPE Rev. No. : 0
SONITPUR, ASSAM
Receiving of Green freshly plucked tea leaves from the gardens of NAHORANI TEA ESTATE for production
of Black CTC and Orthodox Tea at the factory of NAHORANI TEA ESTATE, situated at Sonitpur District, Assam, as per
requirements of the ISO 22000 Food Safety Code by the process of Withering, Rolling & Cutting (incase of
CTC Teas) / Rolling & Sifting (incase of Orthodox Teas), Fermenting, Drying, Sorting & Grading, Packing,
Moisture Testing, Storing and Despatching in Bulk Form to several destinations for Domestic and export
Markets.
To meet the requirements of the Code, a Food Safety Management Systems have been developed within
the factory in order to minimize the risks for achieving product safety and quality.
The Food Business Operator, on applying the requiremnets of ISO 22000, including the general principles of
food hygiene, and where appropriate the relevant codes of practice and the food safety legislation, have
identified critical steps in their various stages of production.
The factory identifies, develops, documents, implements, maintains, controls and reviews adequately
Critical Food Safety and Quality Criteria during production to deliver the tea consignments to its
Buyers.
Date : March 2009

NAHORANI TEA ESTATE 2. NORMATIVE REFERENCES Rev. No. : 0
SONITPUR, ASSAM
The following referenced Documents are appiicable for effecting Food Safety Management System in the
Organization -
1. The latest edition with amendments of ISO 9000 : 2000 Standard on Quality Management Systems.
2. The HACCP Principles developed by the Codex Alimentarius Commission.
3. Periodic notifications from TOCKLAI, Tea Research Association of India.
4. Time to time Circulars from Tea Board of India.
5. Time to time Circulars from Ms Amalgamated Plantations Private Ltd. HO.
6 The requirements of Factory Act , 1948.
7. Circulars from Auction centers at Guwahati and Kolkata
8. Requirements and Principals of ISO 22000 : 2005
9. Latest Edition of PFA
Date : March 2009

NAHORANI TEA ESTATE LIST OF ABBREVIATIONS Rev. No. : 0
SONITPUR, ASSAM
APPL Amalgamated Plantations Private Limited

CCP Critical Control Point
CFM Continuous Fermenting Machine
CTAC Calcutta Tea Auction Center
CTTA Calcutta Tea Trade Association
NHR Nahorani Tea Estate
CP Control Point
CQP Critical Quality Point
CTC Crush Tear Curl
DO Delivery Order
ETP Ethical Tea Partnership
EU European Union
FAM Factory Assistant Manager
FBD Fluid Bed Dryer
FIFO First in First Out
FSM Food Safety Manual
FSMS Food Safety Management System
GHP Good Hygiene Practices
GMP Good Manufacturing Practices
GM General Manager
GTAC Guwahati Tea Auction Center
HACCP Hazard Analysis and Critical Control Point
HO Head Office
HTH Head Tea House
ISO International Organisation for Standardisation
LR Lorry Receipt
MRL Maximum Residue Level
OR Orthodox
PO Purchase Order
PRP Pre - Requisite Programmes
RFU Regulated Feed Unit
SIF Stores Issue Form
SOP Standard Operating Procedures
SRF Stores Receipt Form
SSOP Sanitation Standard Operating Procedures
STG Small Tea Grower
TI Thumb Impression
TRA Tea Research Association
VFBD Vibro Fluid Bed Dryer
UK United Kingdom
Date : March 2009

NAHORANI TEA ESTATE LIST OF AMENDMENTS Rev. No. : 0
SONITPUR, ASSAM
Document No. Changes made Pg No./Rev No. Date
Date : March 2009

NAHORANI TEA ESTATE 3. Terms and Definitions Rev. No. : 0
SONITPUR, ASSAM
A ction-lim it Value : A valu e fo r th e prod uct o r p rocess pa ramete r u nde r co nsid eratio n, d ed uced from
the critical limit value, which indicates that an intervention in the process is required.
A spect : An el emen t of the food b usin ess op eratio n ( p rodu cts, proce sses, P re - re qui site Progra ms,
services) that can interact with the food safety.
C ertification : Actio n by a th ird p arty d emon stra ti ng that ad equ ate confid ence is give n th at a d uly id en ti -
fied product, process or service conforms with a specific standard or other normative document.
C ontrol ( ve rb) : To take a ll ne cessary actio ns to ensu re and ma inta in comp lia nce wi th cri te ria estab li-
shed in the HACCP Plan.
C ontrol ( noun) : The sta te w here in corre ct pro ced ures are b ein g fo llo wed a nd cri te ria are b ein g met.
C ontrol m eas ur e : Any actio n an d activity th at ca n be u sed to preve nt o r e limi nate a foo d safety h aza rd
or reduce it to an acceptable level.
C ontrol m eas ur e , genera l : A mea sure to con tro l a speci fi c p art of the Pre -requ isite Prog rams.
C ontrol m eas ur e, s pe cific : A me asu re to co ntrol a CC P.
C or rec tiv e action : An y a cti on to be take n whe n th e resu lts o f mon itorin g at th e CCP ind icate a lo ss
of control.
Critical Control Point ( CCP) : A step at which it is essential that a specific control measure is applied
to prevent or eliminate a food safety hazard or reduce the risk to an acceptable level.
C ritic al Limit : A cri te rion tha t se para te s a cceptib ili ty from non - a cc eptab ili ty.
Flow Diagram : A systema ti c re prese ntatio n of the se que nce o f steps or op erati ons use d in the pre pa -
ration, processing, manufacturing, packaging, storage, transportation, distribution, handling or offering
for sale of a particular food item.
Food Bus ine ss Ope rator : The p erson or perso ns respo nsib le for en surin g th at the re qui remen ts o f the
food legislation are met within the food business under his / their control.
Food Handle r : Any pe rson wh o dire ctly h an dle s p ackag ed or u npa cked food , foo d equ ipme nt a nd u te n-
sils, or food contact surfaces and is therefore expected to comply with food hygiene requirements.
Date : March 2009

SONITPUR, ASSAM
Food Hygiene : All co ndi ti ons an d mea sures ne cessary to ensu re the safety and su itab ility of fo od at
all stages of the food chain.
Food safe ty : Assura nce that food w ill n ot ca use ha rm to the co nsume r w hen i t is pre pare d or con sum-
ed according to its intended use.
Food suita bility : Assuran ce th at fo od is acce ptabl e fo r h uma n consu mption a ccordi ng to its inten ded
use.
H ACCP ( Ha zard Analysis and C ritic al C ontrol Point) : A system wh ich id entifie s, eva lua te s a nd
controls hazards which are significant for food safety.
H ACCP Audit : A systema ti c a nd in dep en den t exa mina ti on to de te rmine w hethe r the H ACCP system,
including the HACCP Plan and related results, comply with planned arrangements, are implemented
effectively and are suitable for the achievement of its objectives.
H ACCP Plan : A docu ment prep are d in acco rdan ce with the p rinci ple s o f HAC CP to e nsure co ntrol o f
hazards which are significant for food safety in the segment of the food chain under consideration.
H ACCP bas ed Food Safety Sy stem : (a HA CCP sy stem ): The Orga nisa ti ona l stru ctu re, p roce dure s,
processes and resources needed to execute the HACCP plan and meet its objectives.
H ACCP Tea m : Group o f in divi dua ls ( mu lti-di scipl ina ry) w ho d evel op, impl emen t an d mai ntain a
HACCP system.
H azar d : A bi olo gica l, ch emica l or ph ysical a gen t in , or con ditio n of, foo d with the p otentia l to ca use an
adverse health effect.
H azar d Analys is : Th e proce ss of co lle cti ng an d eval ua ti ng in fo rmation o n haza rds an d cond ition s
leading to their presence to decide which are significant for food safety and should therefore be
addressed in the HACCP plan.
Monitoring : The a ct of cond ucting a pla nne d sequ en ce of o bserva ti ons or mea sure ment of co ntrol
parameters to assess whether a CCP is under control.
Date : March 2009

SONITPUR, ASSAM
Pr e-Re quisite Progr amm e ( PR P) : An y speci fi ed an d docu mente d activity or fa cili ty imp leme nted in
accordance with the Codex General Principles of Food Hygiene, Good Manufacturing Practice and
appropriate food legislation, in order to establish basic conditions that are suitable for the production
and handling of safe food at all stages of the food chain.
C or rec tiv e action : An y me asure or activity tha t wi ll be u sed to pre vent, to el imin ate or to re du ce th e
recurrence of causes for existing deviations, defects or any other undesired situation with respect to
food safety.
OPRP : The o pera ti ona l pre requ isite pro gramme i den ti fi ed b y the h azard a nal ysis is essen tial i n orde r to con tro l
the likelyhood of introducing food safety hazards to and /or the contamination or proliferation of Food Safety Hazards
in the product(s) or in the processing enviornment.
Date : March 2009

NAHORANI TEA ESTATE 4. Food Safety Management System Rev. No. : 0
SONITPUR, ASSAM 4.1 General Requirements
NAHORANI TEA ESTATE establishes, documents, implements and maintains an effective Food Safety Management
System and updates it when necessary in accordance with the requirements of the International Standard of
ISO 22000.
The Organization has a well defined Scope to cover the Food Safety Management System which reads as :
Receiving of Green freshly plucked tea leaves from the garden of NAHORANI TEA ESTATE for production
of Black CTC and Orthodox Tea at the factory of NAHORANI TEA ESTATE, situated in Sonitpur District Assam, as per
requirements of the ISO 22000 Food Safety Code by the process of Withering, Rolling & Cutting (incase of
CTC Teas) / Rolling & Sifting (incase of Orthodox Teas), Fermenting, Drying, Sorting & Grading, Packing,
Moisture Testing, Storing and Despatching in Bulk Form to several destinations for Export and Domestic
Markets.
NAHORANI TEA ESTATE ensures that the Food safety hazards that are expected to occur during production are strictly
identified, evaluated and controlled throughout the production process in such a manner that the end product
do not directly or indirectly harm the consumer.
Communication within the Organization and throughout the food Chain regarding the safety issues of its
product are made very simple and clear.
The members of APPL communicates information concerning development, implementation and updating of
the Food Safety Management System throughout the Organization, ensuring the Safety of the product as
required by the International Standard of ISO 22000.
The team members of the Food Safety Management System evaluate periodically and update when necessary
the FSMS to ensure that the system reflects the Organization's activities and incorporates the most
recent information on the Food safety hazards subject to control.
Date : March 2009

SONITPUR, ASSAM 4.2 Documentation Requirements
4.2.1 General
The Documentation structure of the Food Safety Management System includes the following :-
a.) A documented statements of a Food Safety Policy with its related objectives as required under Clause
No. 5.2, is mentioned under Doc. No. NHR-FSM-009, Page 16.
b.)The Documented Procedures ( SOP) and its relevent records as required by this International Standard
are addressed under Doc. No. NHR-PRP-010 to 020, Page nos. 14 to 30.
c.) The Documents required to ensure the effective development, implementation and updating of the FSMS
are mentioned under Doc. No. NHR-PRP-021 - 029, Page 32-49.
4.2.2 Control of Documents

Documents and Records required by the Food Safety Management System are controlled as mentioned
under Clause No. 4.2.3.
The controls ensure that all proposed changes are reviewed prior to implementation to determine their
effect on food safety and their impact on the food safety management system.
All documented procedures are established to define the controls as :-

a.) Prior to release of an issue of any document, the same is approved for adequacy by the Factory Assistant
Manager and released by the Senior Manager
b.) Review, updation and re-approve of documents are also done by the Assistant Manager on consultation with the
Senior Manager of the Tea Estate.
c.) With every amendment or changes done in a document the Revision No. changes. Having attained ten
revisions i.e. with Revision No. 10 , the Issue No. of the Document changes.
The personnel who approves the document, signs on the amendment list, against the amendments done.
d.) At present Revision No. 0 and Issue No. 1 is in use. Amendment done at any page in any document
will be listed out in the Amendment List of the concerned Document for easy reference.
e.) All documents are legible and readily identifiable. The renewed amended documents are filed, controlled
and retained for a minimum of 5 years.
f.) All relevant documents of external origin are identified and their distribution controlled, in the manner as :
The Master set of every Document stamped in Blue is kept with the Senior Manager.
One set of Controlled Document stamped in Blue is kept with the Assistant Manager - Factory.
Another set of Controlled Document stamped in Blue is kept with the General Manager - APPL West
g.)To prevent unintended use of obsolete documents the same is immediately stamped by stamping
OBSOLETE' stamp. To ensure that they are suitably identified, they are retained separately for any future
reference / purpose.
Date : March 2009

List of Documents are as follows : -
Document's Name Document No. Approved and Released By
Food Safety Manual NHR-FSM-001 to 028 , Pages 1 to 86 Anshu Shukla Bhargav Siddhanta
Pre - Requisite NHR-SOP-001 to 060 , Pages 1 to 82 Anshu Shukla Bhargav Siddhanta

Programmes
4 .2 .3 Control of R ecords :
Numerous Registers and Forms are opened to establish record maintenance in order to provide evidence
of conformity to the requirements of the International Standard and effective operation of the FSMS.
The Organization maintains legible Food Safety quality records demonstrating that essential product or
process inspections, tests, analysis and observations conducted for each part of the FSMS as identified in
the HACCP Plan is complete.
All relevant records are stored in good condition and held under secured storage at the Office of the FAM
to prevent their damage and deterioration.
Every record is easily accessible at all times and their maintainence is extended to cover food safety.
All records are retained for a minimum period of two years to enable effective internal and external auditing
of the FSMS. Records of at least three consequtive years are retained for reference purpose, back- track
identification and when specified by customer or regulation / legislation.
All Food safety record entries are endorsed by those making such entries. Who would issue / maintain
which register or form is mentioned herebelow.
Mr. Anshu Shukla, the Assistant Team Leader is responsible for checking all records. On checking the records, he
puts his signature and date of check on the record.
Date : March 2009

List of Registers maintained at factory are as follows : -
Register Nos. List of Registers Maintained By

NHR / R / 001 Weighment Register Weighbridge Attendant
NHR / R / 002 Withering Register Manufacturing Staff/Sirdar
NHR / R / 003 Sifting, Rolling and Cutting Manufacturing Staff/Sirdar
NHR / R / 004 Fermentation Register Manufacturing Staff/Sirdar
NHR / R / 005 Drying Register cum Moisture Test Manufacturing Staff/Sirdar
NHR / R / 006 Moisture Testing, Sorting and Grading Register Sorting Staff/sirdar
NHR / R / 007 Packing,and Storing Sorting Staff/sirdar
NHR / R / 008 Despatch Register Excise Clerk
NHR / R / 009 Pest Control Maintenance Register Assistant Manager - Field
NHR / R / 010 Health Check-Up Register Medical Officer
NHR / R / 011 Laundry & Dress Changing Register Factory OfficeClerk
NHR / R / 012 Stock Register for Sanitizers Factory OfficeClerk
NHR / R / 013 Training Register Senior Manager
NHR / R / 014 Cleaning and Sanitation Register Head Tea House
NHR / R / 015 Register for Inspection and Repair Work Head Fitter
NHR / R / 016 Packing Material Check Register Sorting Staff & Stores Clerk
NHR / R / 017 Daily Check List for Plant Area Head Fitter
NHR / R / 018 Daily Check List for Personnels Factory Office Clerk
NHR / R / 019 Machineries,Equipments,Containers cleaning & maintainence Head Fitter
NHR / R / 020 Internal Audit File Asst Factory Manager
NHR / R / 021 Customer Complaints Asst Factory Manager
NHR / R / 022 Record of Non Conformances and Corrective Actions Asst Factory Manager
NHR / R / 023 Record of Review Meetings Asst Factory Manager
NHR / R / 024 Calibration Records Head Electrician
NHR / R / 025 Analysis Reports on Pesticide, Heavy Metals & Water Tests. Senior Manager
NHR / R / 026 Evaluation of Sub - Contractors Stores Clerk
NHR / R / 027 Record of Mock Product Recall Asst Factory Manager
NHR / R / 028 On line Monitoring Record Asst Factory Manager
NHR / R / 029 On - Site Verification of the Process Flow Chart Asst Factory Manager
NHR / R / 030 Record of Validation of Magnets Head Fitter
NHR / R / 031 List of Registers/ Folders/ Forms Asst Factory Manager
Date : March 2009

List of Forms maintained at factory are as follows : -
Form Name Form No. Maintained By
Local Purchase Order Form NHR / F / 01 Stores Clerk

HO Indent Form NHR / F / 02 Stores Clerk
Dispatch Note NHR / F / 03 Stores Clerk
Stock Statement for Tea NHR / F / 04 Excise Clerk
Stock Statement for Packing Materials NHR / F / 05 Stores Clerk
Daily Garden Report NHR / F / 06 Assistant Manager- Field
Daily Factory Report - Manufacturing Statistics NHR / F / 07 Head Tea House
Invoice cum Gatepass NHR / F / 08 Excise Clerk
Storage Bin Card NHR / F / 09 Excise / Store Clerk
Internal Audit Schedule NHR / F / 10 Senior Manager
Internal Audit Reports NHR / F / 11 Senior Manager
Internal Audit Summary NHR / F / 12 Senior Manager
Record of Effectiveness on Internal Auditing NHR / F / 13 Senior Manager
Training Schedule NHR / F / 14 Senior Manager
Training Records and Effectiveness NHR / F / 15 Senior Manager
Calibration Schedule NHR / F / 16 Asst Manager - Factory
Pest Control Schedule NHR / F / 17 Asst Manager - Field
Bait Location Map NHR / F / 18 Asst Manager - Field
Stock statement of chemicals NHR / F / 19 Stores Clerk
Date : March 2009

PRIVATE LIMITED Page No. : 15a
Mandatory Records Matrix
ISO 22000 Clause Records Required ISO 22000 Present Where in FSMS
5.6.1 Records of Communication FSM-009 Pg 21
5.6.2 Updating of FSMS FSM-030 Pg 88, FSM-022 Pg 75
5.8.1 Records of Management Reviews FSM-009 Pg 23
5.8.2 Input to Management Review FSM-009 Pg 23
6.2.1 Records of agreements or contracts defining responsibility and FSM-009 Pg 23
authority of external experts
6.2.2 Maintain appropriate records of training PRP-026 Pg 34-36
7.2.3 Records of verification and modification FSM-029 Pg 86
7.3.1 Records on information to conduct hazard analysis FSM-016 Pg 42-54
7.3.2 Records to demonstrate that the food safety team has the FSM-010 Pg 25
required knowledge &Experience
7.3.5.1 Verified Flow Diagrams FSM-015 Pg 35-41
7.4.2.1 All food safety Hazards that are reasonably expected to occur FSM-016 Pg 42-54
shall be identified and recorded
7.4.2.3 The justification for and the result of the determination of FSM-020 Pg 68-69
acceptable level for hazards should be recorded
7.4.3 The methodology of evaluation of food safety hazard assessment FSM-017 Pg 59-62
shall be recorded
7.4.4 Result of assesment of control measures FSM-017 Pg 59-62
7.5 Records of monitoring of operational PRPS FSM-018 Pg 63
7.6.1 For each CCP records of monitoring FSM-021 Pg 70-74
7.6.3 Chosen Critical limits shall be documented FSM-020 Pg 69
7.6.4 a Monitoring of CCP- time frame for monitoring FSM-021 Pg 70-74
7.6.4 b Monitoring of CCP- monitoring devices used FSM-021 Pg 71-72
7.6.4 c Monitoring of CCP- applicable caliberation methods FSM-021 Pg 70
7.6.4 d Monitoring of CCP- monitoring frequency FSM-021 Pg 70
7.6.4 e Monitoring of CCP- evaluation of monitoring results FSM-021 Pg 70
7.6.4 f Monitoring of CCP- record requirement and methods FSM-021 Pg 70
7.9 tracibility records shall be maintained FSM-025 Pg 77-78
7.10.1 b The evaluation of causes for non conformity shall be recorded FSM-025 Pg 75-80
7.10.2 Recording the results of corrective actions taken to prevent FSM-025 Pg 75-80
recurence of non conformity
7.10.2 Recording the corrective actions taken to prevent recurence of FSM-025 Pg 75-80
non conformity
7.10.3.2 Records of Sampling,analysis or other verification activities to FSM-026 Pg 81
prove product compliance to acceptable food safety levels
7.10.4 Cause ,extent and result of withdrawl FSM-027 Pg 82-83
7.10.4 Organisation shall verify and record the effectiveness of the FSM-027 Pg 82-83
withdrawl programme
8.2 Result of validation of control measures FSM-028 Pg 84-85
8.3 Basis used for caliberation or verification FSM-028 Pg 85
8.3 Records of the results of caliberation and verification FSM-028 Pg 85
8.4.1 requirements for conducting audits,reporting results,and FSM-029 Pg 86
maintaining records
8.4.1 verification of action taken and reporting of the verification results FSM-029 Pg 86
8.4.3 Analysis of results of verification and the resulting activities shall FSM-029 Pg 87
be recorded
8.5.2 Updating the food safety management system-updating activities shall FSM-030 PG 88
Date : March 2009

NAHORANI TEA ESTATE 5. MANAGEMENT RESPONSIBILITY Rev. No. : 0
SONITPUR, ASSAM 5.1 & 5.2
5 .1 Ma na ge ment Commitme nt : The Top managem ent of the Organization comm its to the dev elopme nt
and implementation of the food safety management system and its continuos improvement by
a.) showing that food safety is supported by business objectives of the organization, as mentioned below :
b.)communicating to all the members of the Organization, the importance of meeting the requirements of
this International Standard, any statutory and regulatory requirements,as well as customer requirements in
relation to food safety.
c.) defining and establishing the Food Safety Policy, which is easily understood and followed by all staff.
d.) conducting management review meetings atleast once in 3 months, to study the effectiveness of the
FSMS and
e.) ensuring the availability of resources for establishing, implementing, maintaining and updating the FSMS.
5.2 FOOD SAFETY POLICY
The Executive Director, defines, documents and communicates the Food Safety Policy of the
Organisation to all the members of the Tea Estates implementing ISO 22000.
The Executive Director - APPL ensures that the Food Safety Policy : -
a.) is appropriate to the role of the Organization in the Food Chain by mentioning that Nahorani , with a legacy
of over 160 years in Tea, are one of the pioneers and committed to delighting its Customers by delivering
Garden Fresh, Safe, Hygienic and Quality tea as per the requirements of the International Standard of
ISO 22000.
b.) conforms to statutory and regulatory requirements and with mutually agreed food safety requirements
of customers.
c.) is communicated, implemented and maintained at all levels of the Organization, by establishing
communication channels with all relevant stake holders.
d.) is reviewed from time to time for continued suitability.
e.) adequately addresses communication by maintaining stringent food safety norms in Cultivation and
Production Processes.
f.) is supported by measurable objectives by training the suppliers and employees on Good Hygiene
Practices and Good Manufacturing Practices.
Executive Director - APPL

The Policy Statement of the Organization is reviewed once in an year. The same is translated in
Hindi and displayed for easy understanding of the factory workers.
Date : March 2009

SONITPUR, ASSAM 5.3
Measurable Objectives planned is mentioned below : -
Policy Measurable objectives Goals and Targets

1. Garden Fresh Good Cultivation practices Upgrade to ISO 22000 systems
by 2009.
Green leaf standards To accept only if Paisometric Count is high &
Damaged Leaf Percentage is low.
2. Safe and Quality Physical, Chemical, Biological hazards Always within acceptable limits.
Tea
Incidents on Product Recall Zero
Finished Tea Test reports Conform to the Norms
ISO 22000 Certification Certification by year 2009

3. Customers Repeat order quantity Improve Quality standards.
Delight
Number of Loyal customers -do-
Market share- Trend analysis -do-

4. Hygienic tea Good Hygiene Practices in processing To verify through Internal Audits
and Cultivation Once in three months.
Establish Communication channels To review needs quarterly through
with Suppliers, Customers, Employees, Management Review meetings
Regulatory Bodies
Impart training to Employees and To cover all employees by May 2009
Suppliers #VALUE!
5.3 Food Safety Management System Planning

The Top Management ensures that the planning of the FSMS is carried out to meet the requirements as
given in Clause No. 4.1, mentioned under Doc. No. NHR-FSM-008, Page 11,as well as the above mention-
ed objectives of the Organization that supports the Food safety.
Moreover, the integrity of the FSMS is maintained when changes to the FSMS are planned and
implemented.
Date : March 2009

SONITPUR, ASSAM 5.4 Responsibility & Authority
5.4 Responsibility and Authority

The Top Management defines and communicates within the Organization, the reponsibilities and authorities
of all the team members in order to ensure the effective operation and maintenance of the FSMS.
The FSMS Team has been formulated by taking the Key Personnels from every Department who are
related with the implementation of ISO 22000 in the factory. Every Team Member is specialized on their
job, reporting system and have an inter-link in between the departments for interchanging their thoughts and
views , thereby initiating record actions.
Designation Responsibilities
Senior Manager Overall management of the estate which involves

full supervision of all estate operations, providing
guidance & advice to estate employees to ensure
all goals & targets set for the year are achieved.
Ensure strict complaince of all Company policies
& values including environmental protection
Prepare development plans, revenue & capital
budgets. Ensure timely & effective address to all
statutory requirements. Ensure harmonious
industrial relations & liasion with government
agencies. Ensure health & safety to all
employees. Interact with suppliers & buyers/
brokers & all other stakeholders to obtain feedback
for continous improvement. Train & develop
managerial staff for future & higher responsibility.
Implementation of FSMS & Resource Management
Assistant Manager - Factory Ensuring achievement of quality in manufacturing
related process. Ensure timely despatches of end
produce and keep expenditure within budget
To keep inventory under control and to ensure that
capex projects are implemented within the given
time & quality.Liason with government officials.
Looking after the admin of the estate in the absence
of the Senior Manager.
He takes up all the job related to ISO 22000
as a team leader.
Assistant Manager - Field Management of field operations and to maximise
harvest of optimum quality of green leaf at
budgeted cost & productivity.
Planning & implementation of field development.
To handle grievances of work force; look into
repairs of residential quarters, ensure availability
of potable water. To ensure hygiene of residential
areas.
Medical Officer To look after the health & hygiene of the employees
at the estate, by conducting health check
programmes. To run the hospital & child care centres
smoothly. To maintain various medical records.
Liason with the Public Health Centres and other
government agencies. Purchase of medicines and
control of hospital inventory. All the above are to be
carried out within the budget.
Welfare Officer To ensure that the Welfare programme of the estate is
properly & fully implemented within the budgeted cost.
To assist the Medical Officer in all Health & Welfare
related activities. To ensure that the residential areas
of the workers & staff are maintained properly.
To maintain a harmonious relationship between the
Management & workers.
Head Tea House To ensure implementation of Company's manufacturing
instructions and manufacture tea conforming to the
required standards set for the estate
Date : March 2009

SONITPUR, ASSAM
Name Designation Responsibilities
Factory Staff - Manufacture To ensure that the Company's manufacture instr-

uctions are implemented and produce teas of the
desired quality.
Factory Staff - Sorting & Packing To ensure correct grading and minimum tea under
process. To check quality of packing material and
the standard of packing. To ensure that there is no
Customer complaint related to faulty packing eg
bag to bag variations etc Quality of Sorting ,
Bulking, cleanliness of sorting room
Factory Staff - Manufacture To ensure that the Company's manufacture
instructions are implemented and produce teas of
the required quality.
Factory Staff - Fitter To ensure minimum downtime and optimum
efficiency of factory machinery
Factory Staff - Electrician To ensure minimum downtime and optimum

efficiency of factory electrical equipment.
Sirdar -Withering To ensure optimum withers and least amount of

damage
Sirdar - Sorting To ensure that quality of stenciling and packing.

To ensure that the machines are kept clean at all times
To ensure that there is no Customer complaint
related to faulty packing eg bag to bag variations etc
Quality of Sorting , Bulking, cleanliness of sorting room
Date : March 2009

SONITPUR, ASSAM 5.5 Food Safety Team Leader
5.5 Food Safety Team Leader
Authorization for Food Safety Team Leader
The Senior Manager is appointed as the Food Safety Team Leader to establish, implement, maintain and update
as per the Internaional Standards of ISO 22000 in the factory of NAHORANI TEA ESTATE, Sonitpur , Assam, in
in addition to his other duties and responsibilities as Senior Manager. He manages the Food Safety
Team and organises its work. He will co-ordinate with all activities of the company to meet the requirements
of the International Standards and report to the top management for review of performance, need for any
improvement, effectiveness and suitability of the FSMS. He will ensure that the preventive Actions are taken
in areas as and when required. He organises preparation of the Food Safety Manual and a set of Pre -
Requisite Programmes. He ensures that his team members get sufficient training and education for imple-
menting FSMS in the Organization.
He organises for Internal and External Audits and takes Corrective Actions to close down the Non-
Compliances. The Food Safety Team Leader is also responsible for establishing liaison with external parties
such as Certification Bodies,Training Organisations, Inspection Authorities, Government Offices on matters
relating to the implementation of FSMS .
In case of absence of the Senior Manager, the Assistant Manager - Factory is empowered to act
on his behalf as a Food Safety Team Leader and carry on all his activities.
General Manager - APPL West
Date : March 2009

SONITPUR, ASSAM 5.6 Communication
5.6.1 External Communication
a. Intende d use a s mentioned under (i) D oc um ent no : NH R- FSM-0 15, pa ge 3 4 dire ction to ma ke te a give n (ii) Storage of te a
mentioned under Docume nt No NHR -PRP-01 9, Pa ge 29 to a ttain better s he lf life .
b. Agreement of Carriage / Fertilizers / Chemical Suppliers / Materials & Spares suppliers
c. Other Organis ation which ha ve an im pa ct on the produc t - Ware houses / re cords to be maintaine d sta ting that the pa rties hav e
be en infor med.
d. Tea Board Notifications
5.6.2 Internal Communication
a. Food safety Team leader should be informed of the following if there is any change.
i. Documents should be changed with change of policy / Product - Refer the document No NHR-FSM-006 Page No. 7
ii Statutory / Regulatory changes
b. Green tea leaf is the raw material
c. All instructions are to be documented.
d. Review meetings and documentation
Date : March 2009

SONITPUR, ASSAM 5.7 Emergency Preparedness
5.7 Emergency preparedness and response :
Formation of Emergency Team :

Anshu Shukla FAM
B. Mahanta 2nd HTH
D. Saikia Electrician
Satyaranjan Das Head Fitter
Suraj Nath Manufacturing Staff - Leader
Swarup Saikia Manufacturing Staff
Procedure for Emergency Preparedness :
1. The staff members of the Emergency Team has been sufficiently trained to act and take necessary step
incase of breakage of fire, flood, mob attack or electrical failure.
2. An Emergency Alarm is placed at the Receiving Station .
3. When any Emergency breaks out, the Alarm Bell rings, cautioning the staff and the Workers at the
factory.
4. They have been trained to leave their work immediately and assemble outside the Office Gate.
5. Incase of Flood or water seepage inside the factory, the tea packages are first covered with thick
tarpaulene to protect them from getting wet.
6. The accumulated water inside the factory is swept down the slope.
7. If water tends to enter into the factory premises from the Entry / Exit Gates, then sand bags are given
at the gates to soak out the incoming / accumulated water.
8. If fire breaks due to Electrical short Circuit or any other reason, then the Electrician is skilled enough
to switch off the Main. If the emergency is within his control he is technically sound to do the needful.
9. The factory workers are trained to operate the Fire Extinguishers located at different locations of the Factory
with the leader.
10. If there is Fire which is out of control, then the Fire Brigrade is called at the following telephone numbers
to set off the blaze. Rangapara - 03714 250096
11. The Food Safety Team Leader is designated to take decisions on Non Conformities related to Food Safety which may be
caused by the emergency.
Date : March 2009

SONITPUR, ASSAM 5.8 Management Review
5.8.1 General :
Nahorani Tea Estate has implemented a procedure for reviewing the Food Safety Management System, once in six
months to ensure continuing suitability, adequacy and effectiveness. The review evaluates the assessing
opportunities for improvement and the need for change to the Food Safety Management System, including
the product safety, policy and objectives.
The review provides evidence of the commitment to improve the FSMS and its performance.
The effectiveness of the Pre - Requisite Programs and other controls implemented to assure food
safety are also documented.
The Food Safety Team Leader is responsible for completing reviews of the FSMS and the Food Safety Plan,
over the Review Meetings conducted once in every six months.
A Food Safety Plan is reviewed when a major change to a product formulation, its process, process controls
or any other factor that has direct impact on food safety and quality arise.
Major changes to a Food Safety Plan that has direct impact on food safety is developed, validated, verified.
All reviews and changes to the FSMS and the Food Safety Plan is documented under Records of Review
Meetings , File No. NHR / R / 023
5.8.2 Review Input :

The input to the Management Review Meetings include the following Agenda :-
a.) The minutes of the previous Management Review Meeting are discussed and the follow -up actions taken.
b.) The Corrective Actions taken to close down the Non - Conformances arisen from the previous External
and Internal Audits.
c.) The changing circumstances in relation to product, process, personnels, packaging and premises which
directly affect Food safety are communicated within the Food Safety Team members.
d.) Emergency situations, its preparedness, withdrawal procedures and personnels responsible for it .
e.) Time to time review and evaluation of the FSMS and its continuous updation.
f.) Communication from Customers, Customer feedback and Customer Complaints are registered, reviewed
and addressed.
g.) External Audits once in 6 months and periodic inspections are held to verify the functioning of the FSMS.
5.8.3 Review Output :

The output from the Management Review Meeting is the minutes of the meeting which includes the decisions
and actions taken in relation to : -
a.) Assurance of Food Safety.
b.) Improvement of the effectiveness of the Food safety Management System.
c.) Adequate resource needs for establishment, implementation, maintenance and updating of the FSMS.
d.) Revisions of the Organization's Food Safety policy and its related objectives.
Date : March 2009

NAHORANI TEA ESTATE 6. Resource Management Rev. No. : 0
SONITPUR, ASSAM 6.1 Provision of resources
Organisational Chart
CMD
Executive Director
Ge ne ral Man age r

We st General Manager Finance
Senior Manager / Manager Engg. Dept

(Food Safety Team Leader)
HR
Materials
Sales & Marketing
R&D
Logistics
Asst Mgr- Factory Asst Mgr- field Medical Officer
Staff Incharge Kamjari Babus Welfare Officer

Sirdars Sirdars
Workers Field Workers
Date : March 2009

SONITPUR, ASSAM 6.2 Human Resources
6.2.1 : General
6.2.2 : Competence, awareness and training

The Food SafetyTeam has been formulated by taking the Key Personnels from every Department who are
related with the implementation of ISO 22000 in the Factory. Every Team Member is specialized on their
job and have an inter-link in between the departments for interchanging their thoughts and views.
Name Designation Qualification / Responsibilities

Experience
Mr. Bhargav Siddhanta Senior Manager - BSc. - 22 yrs Refer to

Mr. Anshu Shukla Assistant Manager - B.A. - 8 yrs Doc no NHR-FSM-009, Page 18 to 20
Mr. R.K. Mishra Assistant Manager - B.Sc. - 5 yrs "
Mr. Gautam Baruah Assistant Manager - B.Com - 3 yrs "
Dr. B.N. Phukan Medical Officer - MBBS - 6 yrs "
Mr. P.K.Baruah Welfare Officer - B.Sc. - 19 yrs "
Mr. Clement Minz Welfare Officer - B.A. - 11 yrs "
Sh. Prasanna Hazarika Head Tea House - HSLC - 28 yrs "
Sh. B. Mahanta 2nd Head Tea House - HSLC - 16 yrs "
Sh. Suraj Nath Factory Staff - Manufacture - BA - 7 yrs "
Sh. Swarup Saikia Factory Staff - Manufacture - BA - 5 yrs "
Sh. Satya Ranjan Das Factory Staff - Fitter - ITI Diploma - 7 yrs "
Sh. Dimbeswar Saikia Factory Staff - Electrician - ITI Diploma-30 yrs "
Sh. Sunil Karmakar Sirdar -Sorting 12 Yrs "
Qualification criteria for new members to be inserted in the Food Safety Team : -
1. Must be Regular in Attendance.

2. Must have knowledge and experience in Tea.
3. Must be diligent in his / her work.
4. Ability to communicate and correspond.
5. Must have minimum Educational Qualification.
6. Must have good hygiene practice.
Date : March 2009

NAHORANIASSAM
SONITPUR, TEA ESTATE 6.6.2
Resource
HumanManagement
Resources Rev. No. : 0
In case of absence of the key personnels, their functional responsibilities are undertaken by the
following heads : -
Mr. B. Siddhanta is represented by Mr. Anshu Shukla
Mr. Anshu Shukla is represented by Mr. R.K. Mishra
Mr. R.K. Mishra is represented by Mr. G. Baruah
Mr. G. Baruah is represented by Mr.R.K. Mishra
Dr. B.N.Phukan is represented by Mr. P.K. Baruah
Mr. P.K. Baruah is represented by Mr. Clement Minz
Mr. C. Minz is represented by Mr. P.K. Baruah
Date : March 2009

SONITPUR, ASSAM
6.3 Infrastucture :
The Senior Manager prepares a Budgetary Plan on checking the implementation work to be done at the
factory for ISO 22000, on basis of the Gap Analysis Report which he submits to the G.M - West.
The G.M - West on receipt of the plan calls for a meeting with the Senior Manager. They discuss the issues,
judge the necessities, prioritize which portion to be done when and how, finalises the plan and submits to
GM - Finance.
The G.M - Finance on dicussing the issue with G.M - West submits the budget to the Executive Director.
On receipt of the Budgetary Plan, the Executive Director calls for a meeting with the G.M - West and
G.M - Finance .
The E.D is the ultimate Decision Maker and Provider of Resource Supply as needed by the Food Safety
Team to develop,implement and maintain FSMS in the factory. He can either sanction the bubget, or holds
or release priority wise.
When the factory is required to take any corrective action against any Non - Conformances arising from
the External or Internal Audit or rectify any verification procedure or develop any operational improvements
as indicated or desired by any Customer, the G.M - West examines the issues and submits the
proposal to the Executive Director through the G.M - Finance for provision of appropriate resources to
ensure food safety.
6.4 Work environment :
The resources provided for the establishment and maintainance of the infrastructure needed to implement the
requirements of the International Standard of ISO 22000, is listed below:
EOR CAPEX
Painting/ Markers
Floor Repair Pesto-O- Flash
Tarmacing New Area/Road Drain cover/tiling/Paint
Latrine Repair/Complete Bird Proofing
Hygiene Station
CAPEX Over lap of dry and wet Tea
Uniform
Shatter proof Light Footwear
Epoxy Paint Posters/Photograps
Bird Proofing Glow Sign (Factory Entrance)
Date : March 2009

NAHORANI TEA ESTATE 7. Planning and realization Rev. No. : 0
SONITPUR, ASSAM of safe products
7 .1 Genera l : Nah oran i Te a Estate pla ns and deve lop s the o pera ti on al pro cesses ne ede d for th e real izatio n of sa fe
products. This includes the development, implementation and operation of the Pre-requisite programmes, the
operational PRP's and the Food Safety Plan which ensures the effectiveness of the planned activities and
any changes to those activities.
7 .2 Pr e-re quisite Progr amm es (PR P's) -
7 .2 .1 Prereq uisi te Pro gramme s are de velo ped , estab lish ed , impl emen te d and ma in ta ine d to a ssist
in controlling the following : -
a.) The likelihood of the presence of Food Safety Hazards into the product through the Work environment.
b.) Cross Contamination between the products which includes Biological, Chemical and physical
contaminations.
c.) The levels of Food Safety Hazards in the product and the concerned product processing environment.
7.2.2 The PRP 's are : -
a.) Appropriate to the Organizational needs with regard to Food Safety. Refer Doc Nos. NHR-PRP-003 to
NHR-PRP- 009 , Page 4 to 14 .
b.) Appropriate to the size and type of the operation and the nature of the products being manufactured
and handled. Refer Doc Nos. NHR-PRP- 010 to NHR-PRP- 021, Page 15 to 32.
c.) Implemented as General Programmes across the entire production system or as programmes applicable
to a particular product or operational line.Refer Doc Nos. NHR-PRP-022 to NHR-PRP-025 , Page 33 to 38.
d.) All documents are approved by the Food Safety Team Leader.
7.2.3 While selecting and establishing PRP's , NHR considers and utilizes appropriate information in
relation to Statutory and Regulatory requirements . Refer Doc. No. NHR-PRP-026 , Page Nos. 39 to 44.
The details of the pre-requisite programmes are outlined under Doc. No. NHR-PRP-028 to NHR-PRP-056
Page Nos. 46 to 78.
a.) Refer Doc . No. NHR -PRP-027 , Page 45 to 47.

b.) , c.) , d.) - Refer Doc No. NHR - PRP - 028 to 033, Page 48 to 53
Date : March 2009

NAHORANI TEA ESTATE 7. Planning and realization Rev. No. : 0
SONITPUR, ASSAM of safe products
e.) Refer Doc. NO. NHR - PRP- 034, Page 54 & 55.
g.) Refer Doc . No. NHR - PRP- 035 , Page 56.
h.) Refer Doc. No. NHR - PRP - 036 to 050 , Page 57 to 71.
i.) Refer Doc. No. NHR - PRP- 051, Page 72.
j.) Refer Doc. No. NHR-PRP-052 to 055, Page 73 to 76.
k.) Refer Doc. No. NHR- PRP-056, Page 77 to 78.
The Verification of PRP's are planned and modified as necessary. Records of Verifications and
modifications are maintained as per list of registers and files mentioned under Doc No. NHR-FSM-008,
Page Nos. 14 and 15.
The Documents specify how the activities included in the PRP's are managed.
Date : March 2009

NAHORANI TEA ESTATE 7.3 Preliminary steps to enable Rev. No. : 0
SONITPUR, ASSAM Hazard Analysis
7 .3 .1 Genera l : Al l rele van t in fo rmation i .e the p roce ss step s , nee ded to co ndu ct the ha zard a nal ysis are
collected, maintained, updated and documented. Corresponding records are also maintained.
7 .3 .2 Food Sa fety Team :

The Food SafetyTeam has been formulated by taking the Key Personnels from every Department who are
related with the implementation of ISO 22000 in the factory. Every Team Member is specialized on their
job and have an inter-link in between the departments for interchanging their thoughts and views.
The members of the Food Safety Team have a combination of multi- disciplinary knowledge and experience
in developing and implementing the food safety management system. This includes the products, the
processes, equipments and the food safety hazards within the scope of the food safety management
system.
The Educational Qualifications and experience of the Food Safety Team members are detailed under
Doc. No. NHR-FSM-010 Page Nos 24 and 25.
Date : March 2009

NAHORANI TEA ESTATE 7.3.3 Product Characteristics Rev. No. : 0
SONITPUR, ASSAM
7.3.3.1 Raw materials, ingredients and product - contact materials : -
Raw Materials : -
For the production of Black Tea, the raw material used is green tea leaves only.
Tea leaves of Indian origin, grown in the valley of Assam are processed to make both CTC and Orthodox
teas.
Tea Leaves, biologically known as Camellia Sinensis is manufactured solely and exclusively from the
shoot of the tea bush comprising of leaves, buds and tender stems. The plucked tea leaves are transported to
the Factory from the field in trailors/ LCVs in nylon bags/ loose form. The food safety criteria for green leaf from own fields are checked at
the time of receiving.The leaf is stored in withering troughs under controlled enviornments for 16 to 20 hours and then
are processed through withering, rolling, cutting (in case ofCTC teas) / rolling (in case of Orthodox teas) fermenting,
drying, sorting and grading before been packed and despatched.Though the processed tea leaves have a blackish brown in appearance,
the colour, liquor, vigour, strength,taste and cup quality differs from region to region, season to season, crop to crop for one particular grade.
Ingr edie nts : There i s n o other in gre die nt u sed / req uire d in the p rodu cti on of Bla ck Tea L eave s.
Product - Contact Materials : -

The product - contact materials used at different stages of production and their concerned hazards are
described under Doc. No. NHR-PRP- 38 ,Page No.59
NHR adheres to PFA rules in using / selecting the product contact materials. Food Grade / Toxicological /
Chemical Migration Certificates are taken from the respective Suppliers / Manufacturers to suffice the Food
Safety requirements.
The descriptions are updated when required.
Date : March 2009

SONITPUR, ASSAM 7.3.3.2 Characteristics of End Products
Product Name Black Tea - CTC in Bulk Form.
Composition Tea Leaves only, manufactured solely and exclusively from the shoot of the Tea
Bush comprising of leaves , buds and tender stems.
End Product Charac- Appearance - Blackish Brown granules.

teristics Taste - Strong liquour, flavour, vigour, strength with mild aroma and good cup quality.
Grades BOPSM, BOP, PF, PD, BPS, BP, Dust, Churamani Dust.
BP1, PF1 & Dust1.
Characteristics -
Biological Moisture content - within 3.5 % .
Chemical Pesticide residue - M.R.L as prescribed by T.R.A .
Physical Nails / iron particles and all types of foreign alien materials - 0.001% to 0.1%.
Method of Preservation The seal of the paper sacks / jute bags / woven bags are not to be opened.
Packaging Primary In Jute bags , PP woven sacks and Paper Sacks.

Jute Bags and PP woven sacks with liners are packed at normal room temperature in an absolute dry area
with dry hands.
Transportation Tea filled paper sacks and jute bags are loaded in a lorry / truck covered with
tarpauline to protect from rain and dust during transit.
Storage Conditions On rails, at room temperature,away from the wall & ceiling above the floor conforming to Prevention of Food
Adultration Act and any other specific customer requirements.
Distribution Method Ready consignments are loaded in truck / lorry as per the the instruction of the H.O.
Shelf Life 2 years under the given storage conditions.
Special Labelling Nt.Wt., Gr.Wt., Inv. No., Grade, Garden Name, Bag No., Produce of India Label
marked / stencilled on the packages and name of the Company.
Customer Preparation Shipping Marks are given on the packages for easy identification, handling and
usage by the customer.
Where will it be sold Domestic / Importing Country
Date : March 2009

SONITPUR, ASSAM 7.3.3.2 Characteristics of End Products
Product Name Black Tea - in Orthodox Form.
Composition Tea Leaves only, manufactured solely and exclusively from the shoot of the Tea
Bush comprising of leaves , buds and tender stems.
End Product Charac- Appearance - Blackish Brown leaves.

teristics Taste - Mild liquour, flavour, vigour, strength with mild aroma and good cup quality.
Grades TGFOP1, TGFOP, GFBOP, FBOP, GBOP,FOP, FOF,

GFOP, OBPS, BOP1, OPD.
Characteristics -
Biological Moisture content - to be within 3.5% .
Chemical Pesticide residue - MRL as prescribed by T.R.A .
Physical Nails / iron particles and all types of foreign alien materials - 0.001% to 0.1%.
Method of Preservation The seal of the paper sacks / jute bags / woven bags are not to be opened.
Packaging Primary In Half Sized / Full Sized paper sacks and PP woven sacks.
Paper sacks and PP woven sacks with liners are packed at normal
room temperature in an absolute dry area with dry hands.
Transportation Tea filled paper sacks and jute bags are loaded in a lorry / truck covered with
tarpauline to protect from rain and dust during transit.
Storage Conditions On rails, at room temperature,away from the wall & ceiling above the floor conforming to Prevention of Food
Adultration Act and any other specific customer requirements.
Distribution Method Ready consignments are loaded in truck / lorry as per the the instruction of the H.O.
Shelf Life 2 years under the given storage conditions.
Special Labelling Nt.Wt., Gr.Wt., Std.No., Inv. No., Garden Name, Lot No., Produce of India Label
marked / stencilled on the packages, name of the Company.
Customer Preparation Shipping Marks are given on the packages for easy identification, handling and
usage by the customer.
Where will it be sold Domestic / Importing Country.

Date : March 2009

NAHORANI TEA ESTATE 7.3.4 Intended Use Rev. No. : 0
SONITPUR, ASSAM
Target Consumer : General Public in the Country and Consumers in the Importing Countries as
Beverage or Health Drink.
The expected handling procedure of the end product is outlined under the Directions to make Tea.
Introduction of physical hazards during blending and packing if GMP not followed or any unintended or
unexpected mishandling causing damage to packaging and inappropriate warehousing resulting in high moisture leading
to mouldy teas and/ or misuse of the end product will not give the expected results.
Directions to make Tea : -
1. Rinse the Tea Pot, Cups and the Strainer.

2. Boil water to 100 degrees centigrade.
3. Measurement of tea leaves is taken as per the cup size / the liquor wanted.
4. Put tea leaves into the boiled water.
5. Brew the tea leaves as per the desired liquor.
6. Check the infusion.
7. Strain out the liquor.
8. Add sugar and / or milk to taste.
Date : March 2009

NAHORANI TEA ESTATE 7.3.5 Flow diagrams, Process steps Rev. No. : 0
SONITPUR, ASSAM and Control Measures
7.3.5.1 Flow Diagram for CTC Tea :
Receiving of Fresh , Green Tea Leaves from the Gardens
Loading onto the Withering Trough -------------------------- Thru Mono Rail

| |
Sifting through RFU Sifter -------------------------- -----------|
|
Rolling on Rolling Table / Passing
through Rotovane Machine
|
----------------------- Crushing, Tearing, Curling ( CTC ),
I Three cuts in Tandem
I |
I Fermenting through CFM -------------------------- Conveyor Belt
I | |
I Drying -------------------------- --------------|
I |
Ball Mall ------------------------ Ball Separator
|------------------------- Fibre Extractors

Through Conveyor
I
I-------------------------
Primary Sorting
Belt and Magnet |
I-------------------------- Hopper of the Mother Sorter for
I Secondary Sorting
I |
Recycled------------------- Grading & Fibre Extracting on passing
through Magnets and Mesh Sorters with ---------------------------- Tea waste
Fibre Extractor Rollers
|
Moisture Testing ----------------------------Gapping
| |
----------------------------------I
Passing through High Density Passing through Pre-Packing Sorters with
Java Separator Magnets & Mesh with Fibre Extractors
Spreading over Bulking Sheets Incoming check on packing material

|
Pac king & we ighing ---------------------- Storing--------------- Despatch
Inprocess checking of packing material

Date : March 2009

7.3.5.1 Flow Diagram for Orthodox Tea :
Receiving of Fresh,Green Tea Leaves from the Gardens

|
Loading onto the Withering Trough , -------------------------- Thru Mono Rail
Withering & Pre - Conditioning |
| |
|------------- Rolling on Rolling Table -------------------------- --------- ----|
| |
1st Rolling------- Sifting (A) / Ghooghie Operation ---------1st Fine----------------- ---|
| |
2nd Rolling Sifting (B) |
| | |
3rd Fine ----------------------------------
----3rd Rolling |
| | |
Fermentation 2nd Fine _____________|
Through Mono --------- 1st Fine
Rail |
|------------------------------ Drying
|
|------------ Hopper of the Myddleton Sorter with ----------- -|
Through Conveyor Dimple Tray |
Belt and Magnet | |
|------------ Ghooghie Operation & Passes through |
Wire Mesh for Primary Sorting ------------------------ Goes To Tocklai
| | Tea Breaker
Macintosh Sorter for Secondary Sorting -------------| |
| |
Grading & Fibre Extracting on passing ---------------------------------------- |
through Magnets & Mesh Sorters
with Fibre Extractor Rollers
| Incoming check on packing material
Spreading over---------- Moisture Testing -------------------------- Gapping
Bulking Sheets | |
|--------------- Packing on Weighing by the -------------------------- ------------ -|
Packing Machine
|
Storing-----------------------------------------
Despatch
Date : March 2009

Keeping in hand the Flow Diagram and Process Flow Chart, Doc NO. NHR-FSM-011, Page 33, 36 & 37 for
CTC Teas, and Pages 34, 38 & 39 for Orthodox Tea the Food safety Team alongwith their Leader, goes
round the plant physically for on-site verification of the production process atleast once in an year.
They tally the Process Flow Chart and the Flow Diagram with the On-line Operation of the factory.
Their findings are noted and suggestions are considered.
The Record for On - Site Verification of the Process Flow Chart is maintained under Register No.
NHR / R / 029.
Date : March 2009

NAHORANI TEA ESTATE 7.3.5.2 Description of Process Steps Rev. No. : 0
Process Step for CTC Primary Production
Refer to Attachment
Date : March 2009

Process Step for CTC Secondary Production
Refer to Attachment
Date : March 2009

Process Step for Orthodox Tea ( Primary Production )
Refer to Attachment
Date : March 2009

Process Step for Orthodox Tea ( Secondary Production )
Refer to Attachment
Date : March 2009

NAHORANI TEA ESTATE 7.4 Hazard Analysis Rev. No. : 0
SONITPUR, ASSAM
7 .4 .1 Gener al : The Food Sa fety Tea m conducts a Ha zard Analysis a t e ver y step of ope ration and
determines which hazards are to be controlled, how it is to be controlled, the degree of control and the
combination of control measures to be used, thus ensuring food safety throughout the management system.
7.4.2 Hazard Identification and Determination of Accepable levels :

The Food Safety hazards which are likely to occur in relation to tea and its corresponding manufacturing
processes are identified and recorded under Doc. No. NHR-FSM-019, Page No. 43 to 54.
7.4.2.2 While identifying the hazards, a.) all the Manufacturing processes are considered ;
b.) all the process equipments involved are considered ;
c.) all the links in the Food Chain (i.e. before and after the Current Food Handler) are considered.
7 .4 .2 .3 The acce ptab le le vel of th e Fo od Sa fe ty Ha zard in the e nd p rodu ct - te a is ide ntifie d by th e conce pts
and Principles utilised for determining the risks that comply with the legal requirements supported by CTTA
Rule Book and Approval List on Pesticides from T.R.A.
7 .4 .3 Ha zard Ass ess me nt : A Ha zard asse ssment is cond ucted to de te rmine tha t for the id entifie d fo od
safety hazard, whether its elimination or reduction to acceptable levels is essential to the production of
safe food
Each Food Safety hazard is evaluated according to the possible severity of adverse health effects and the
likelihood of their occurrence. A Risk Analysis of Likelihood - Low, Medium and High and its Severity is
documented as below and considered while conducting Hazard analysis.
S E V E R I T Y
L High Medium Low
I
K High H/ H H/ M H/ L
E
L Medium M / H M/M M/L
I
H Low L/ H L /M L/ L
O
O To be Yes Yes Not
D judged by Required
CCP Decision
SIGNIFICANCE Tree
Date : March 2009
HAZARD ANALYSIS WORKSHEET
Estate Name : NAHORANI TEA ESTATE Doc No. : NHR-FSM-016

Estate Address : Sonitpur, Assam, India Issue No. 1
Page No. : 43
Rev. No. : 0
Product Description : Indian Black CTC Tea in Bulk Form - BPS, BOP, BOPsm, BP, PF, PD, D, CD, BP1, PF1, D1
TG1,TG,GFOP,FOP,BPS,FBOP,GFBOP,GBOP,GOF/FOF,OD,OCD,BOP1,OPD
Method of Storage and Distribution : Packed in Paper Sacks / Jute Bags / Woven Sacks and stored on Wooden Battens
Intended use and Customer : Common Public from the Domestic market and Imported by Overseas Buyers for further processing /packing.
-1 -2 -3 -4 -5 -6 -7 -8
(S, No.) Process Step Identify potential Are any potential Indicate Likelihood Justify your decision What preventive Is this step a
Hazards food safety(PFS) / & Severity of why the hazard is measures can be Critical Control
introduced, Quality hazards Hazard High-H significant or not? applied to prevent the Point / Critical
controlled or significant(QHS)? Medium-M significant hazard? Quality Point Yes
enhanced at this Low-L / No
step
1 Receiving BIOLOGICAL PFS Likelihood - M Damaged leaves if 1. Pluckers instructed not CONTROL POINT-
Presence of Severity - H mixes with the good to compress the leaves 1
bacterial pathogens ones will affect cup into the basket.
quality 2.Immediate
transportation from
garden to factory.
CHEMICAL PFS Likelihood – M Presence of Pesticide 1. Avoid banned CCP - 1

Presence of Heavy Severity - H above M.R.L and chemicals & use
metals and unlimited use of in- approved chemicals
Pesticide Residue organic manures with within permissible limits.
compositions unknown 2.Plucking to be done
is harmful for human after minimum recomme
consumption. nded period of
application of pesticides
and manures.
PHYSICAL Nil Likelihood- N.A N.A NO

Nil Severity -
QUALITY Nil Likelihood- N.A N.A NO
Severity –
Doc No. : NHR-FSM-016
Issue No. 1
Page No. : 44
Rev. No. : 0
-1 -2 -3 -4 -5 -6 -7 -8
Hazards food safety / Quality & Severity of why the hazard is measures can be Critical Control
introduced, hazards Hazard High-H significant or not applied to prevent the Point / Criti- cal
controlled or significant? Medium-M significant hazard? Quality Point
enhanced at this Low-L Yes/No
step
2 Withering BIOLOGICAL Nil Likelihood - N.A N.A NO

Nil Severity –
CHEMICAL Nil Likelihood - N.A N.A NO
Nil Severity -
PHYSICAL PFS Likelihood – H Chances of dust & Providing sliding netted NO
Severity - H foreign matter windows or installing Fly
Dust, flies, foreign contamination remain Catchers.
matter through atmospheric air
contamination as the troughs are not
covered inside the
factory area.
QUALITY Over or QHS Likelihood – L Affects the cup quality. Strict monitoring,even CQP - 1
low withering Severity - M spreading, use of heater
as necessary.
3 Sifting BIOLOGICAL Nil Likelihood - N.A N.A NO
Nil Severity -
PHYSICAL PFS Likelihood – L N.A N.A NO
Severity - L
Dust, dead flies &
foreign alien
materials
Nil Severity -
QUALITY Nil Likelihood- N.A N.A NO
Severity-
4 Rolling and Nil
BIOLOGICAL PFS Likelihood – M Improper cleaning of Thorough cleaning of NO
Cutting Microbial Severity - H machine & surrounding machine after every
Growth floor will allow the operation. Scrubbing
processed material to and cleaning of the floor.
remain stuck favouring
microbial growth to
affect black tea quality.
Page : 45 :
-1 -2 -3 -4 -5 -6 -7 -8
Process Step Identify potential Are any potential Indicate Likelihood Justify your decision What preventive Is this step a
introduced, hazards Hazard High-H significant or not applied to prevent the Point / Criti- cal
controlled or significant? Medium-M Low-L significant hazard? Quality Point Yes/
enhanced at this No
step
4 Rolling and CHEMICAL Nil Likelihood – M N.A N.A NO

Cutting Nil Severity - H
PHYSICAL PFS Likelihood – M Potential of metallic Periodic maintenance & CONTROL POINT
Metallic Severity - H contamination due to review of machine -2
Contamination improper maintenance condition.Magnets placed
& machine fatigue. at CTC Bank & at the
Mother Tray -mouth of
the Sifter for colle-ction of
iron pieces.
QUALITY QHS Likelihood - L Improper feeding & Proper setting of the CQP - 2
Severity - M adjustments affects cup machine and uneven
Excessive juice quality. feeding of the withered
extraction leaves.
5 BIOLOGICAL Nil Likelihood - N.A N.A NO

Nil Severity -
Ghooghie
Operation
Nil Severity -
PHYSICAL Nil Likelihood - N.A N.A NO

Nil Severity -
QUALITY- Density, QHS Likelihood - M Appearance Differs, Periodic Cleaning. CQP-3

make & style of Severity - M May not be liked by
leaves will differ Customers
Page : 46 :
-1 -2 -3 -4 -5 -6 -7 -8
introduced, hazards Hazard High-H significant or not applied to prevent the Point / Critical
controlled or significant? Medium-M Low-L significant hazard? Quality Point
enhanced at this Yes / No
step
6 Fermenting BIOLOGICAL PFS Likelihood - L Improper cleaning of Fermenting machine is NO

Severity - H fermenting machine , required to be completely
Microbial Growth which favours growth of dry before use. The
yeast, mould, bacterial Conveyor Belt is either of
proliferation & food grade material or of
production of fungal Stainless Steel.
toxins which cannot be
later eliminated from tea
during the subsequent
processes.
CHEMICAL PFS Likelihood – L Residue of washing Thorough cleaning with NO

Washing Severity - M chemicals can affect approved detergents and
Chemicals fermentation quality and scraping with water are
food safety. required to move out the
traces of detergents.
PHYSICAL PFS Likelihood - L Contamination occurs Fermenting machine is NO

Human Severity - H due to uncontrolled not to be handled by
contamination with movement of personnel anyone else except for
extraneous matter in the earmarked area. those who are assigned
the job.
QUALITY QHS Likelihood - L Spoils the tea quality, Strict monitoring, CQP - 4
Under or Severity - H appearance and sweet maintaining time, proper
Over fermentation aroma. humidity & minimum
difference between dry &
wet bulbs.
Page : 47 :
-1 -2 -3 -4 -5 -6 -7 -8
step
7 Drying BIOLOGICAL PFS Likelihood - L To bring down the 1. Moisture outrightly CCP- 2
Presence of Severity - M moisture to an checked after drying, if
Moisture acceptable level.Higher found above the permissi
moisture content may ble limit, refiring is done.
lead to microbial growth 2. Packing is done
, thus affecting food ASAP after firing.
safety & black tea
quality.

Nil Severity -
PHYSICAL Nil Likelihood – N.A N.A NO

Nil Severity -
QUALITY QHS Likelihood – L Cup quality Strict monitoring, proper CQP - 5
Severity - H deteriorates, shelf life of feeding into the dryers
Improper tea reduces. and maintaining the
Firing temperature.
8 Sorting & BIOLOGICAL PFS Likelihood – N.A N.A NO

Grading - Nil Severity -
Primary
CHEMICAL Nil Likelihood – N.A N.A NO

Nil Severity -
PHYSICAL PFS Likelihood - L Potential of metallic Periodic check and CONTROL POINT-
Metallic Severity - H contamination remains maintenance of magnetic 4
contamination, from the wire mesh of arrestor. All foreign
presence of foreign the Sifters. Collection materials collected by
alien materials and of foreign alien the Sifter to be gathered
ferrous particles materials and ferrous in a separate box &
particles. disposed off outrightly.
Page : 48 :
-1 -2 -3 -4 -5 -6 -7 -8
step
QUALITY Nil Likelihood – N.A N.A NO

Nil Severity -
9 Sorting & BIOLOGICAL PFS Likelihood – N.A N.A NO
Grading - Nil Severity -
Secondary

Nil Severity -
PHYSICAL PFS Likelihood - L Potential of metallic Periodic use and CONTROL POINT
Metallic Severity - H contamination remains maintena-nce of -5
contamination, from the wire mesh of magnetic arrestor. All
presence of foreign the Sifters. Collection foreign materials colle-
alien materials of fereign alien cted by the Sifter to be
materials. gathered in a separate
box & disposed off
outrightly.

Nil
Severity -
10 Fibre BIOLOGICAL Nil Likelihood - Severity N.A N.A NO

Nil -
Extraction
with Mesh CHEMICAL PFS Likelihood – L N.A N.A NO
Nil Severity - H
Sorters
PHYSICAL QHS Liklihood - L N.A N.A NO
Nil Severity - H
QUALITY QHS Liklihood -M If not controlled may not Passed through CQP-6
Presence of Severity - H be acceptable by winnowing tunnel to
fluff buyer. reduce the presence of
fluff / good extraction
system
Page : 49 :
-1 -2 -3 -4 5 6 7 8
enhanced at this
step
11 Purchase & BIOLOGICAL PFS Likelihood – M Packing / storage Incoming packing materials No
Storage of Packing If the packing Severity - H materials if contain water are checked to be
Materials materials used are not molecules, will affect the completely dry before use
dry, moisture gathers. tea inside. Can form and the storage pallets or
mould or fungii also. wooden battens fumigated /
ASCU treated.
CHEMICAL Nil Nil Likelihood – N.A N.A NO

Severity -
PHYSICAL PFS Likelihood – M Affects quality of the tea, Paper sacks inserted in NO
Size and shapes of the Severity - H non- acceptance by buyer Shapers to get the correct
packs disturbed shape.
QUALITY QHS Likelihood – L Affects the End - Random visual check. All CQP - 7
Holes in soft packs, Severity - H Product,non-acceptance packing materials coming
The inner lining of the by buyer dirctly in contact with tea
packaging material if should be of food grade
not having food grade Quality.
quality.Smell of
adhesive used.
12 Packing - BIOLOGICAL Nil Likelihood - Severity N.A N.A NO

Primary & Nil -
Secondary
Grades
CHEMICAL PFS Likelihood – L If food grade quality Food grade plastic NO

Chemical Severity - H inner material not used, material of specified
contamina-tion from the packed material will quality is required to be
inner liner of chest / be chemically used.
jute bag contaminated due to
migration.
Page : 50 :
-1 -2 -3 -4 -5 -6 -7 -8
step
12 Packing - PHYSICAL PFS Liklihood - L If not controlled may not Passed through magnets CCP - 3
Primary & Presence of Severity - H be acceptable by of different machines &
Secondary ferrous particles and buyers. Consumption Conveyor Belts to reduce
Grades metal magnetic of such contaminated the presence of ferrous
impurities. tea is harmful for particles and metal
human health. magnetic impurities.
QUALITY QHS Likelihood – M 1. Affects the packed Random visual check CQP -8
Use of Severity - H tea. 2. May not be
improper or poor acceptable to the buyer.
quality of packing
materials
13 Moisture Testing BIOLOGICAL PFS Likelihood – L Not harmful for human Moisture content is Control Point - 6
and Gapping Microbial Growth Severity - M consumption checked with Moisture
Meter. If found more than
permissible limit, the tea
is sent for gapping.

Nil Severity -
PHYSICAL PFS Likelihood - N.A N.A NO
Nil Severity -
Nil
Severity -
14 Storing Biological - PFS Likelihood – M Due to improper Tea to be stored in a NO
Presence of water Severity - H storage material, damp proof covered area
molecules on the moisture inceases. with impervious flooring,
pallets used for Potential of microbial on wooden battens /
storage of tea . growth remains. The pallets or platforms which
micro-organisms may are totally dry.
release toxins, which
affect the tea.
Page : 51 :
-1 -2 -3 -4 -5 -6 -7 -8
step
14 Storing CHEMICAL Nil Likelihood – N.A N.A NO

Nil Severity -
PHYSICAL Nil Likelihood – N.A N.A NO
Nil Severity -
Nil
Severity -
15 Despatch / BIOLOGICAL PFS Likelihood –H The Floor of the truck if The truck should be 'Fit NO
Transporta - tion Formation of Severity - H not sufficiently dry and to Carry Tea', with
the Following Bacterial Pathogens odourfree, moisture will tarpaulene cover all
Link in the Food accumulate & spoil the around to protect from
Chain tea in transit. rain during transit.

Nil Severity -
PHYSICAL Nil Nil Likelihood – N.A N.A NO
Severity -
QUALITY QHS Likelihood – L Will affect the end Strict Physical inspection CQP- 9
Tearing off / Damage Severity - M product while loading
of Packages.
16 Process BIOLOGICAL - Nil Nil Likelihood - Nil N.A N.A NO

Equipments & Severity -Nil
installation of
small
machineries.
CHEMICAL - Nil Nil Likelihood - Nil N.A N.A NO

Severity -Nil
Page : 52 :
-1 -2 -3 -4 5 6 7 8
enhanced at this
step
16 Process PHYSICAL - PFS Likelihood- M Harmful for human Physical inspection and NO
Equipments & Presence of small Severity - H consumption, can passing thru magnets
installation of machine parts, nuts cause sickness and meshes.
small & bolts while
machineries. assembling
QUALITY - Nil QHS Likelihood-Nil N.A N.A NO

Severity - Nil
17 Layout of the BIOLOGICAL PFS Likelihood - M Cross - Contamination Uni-directional flow from N0
facility, location Growth of bacterial Severity - H will affect the tea. the entry of raw materials
of rooms, routing Pathogens to the exit of Finished
and ventilation products is maintained.

Nil Severity
PHYSICAL Nil Likelihood – N.A NO NO
Nil Severity –
QUALITY Nil Nil Likelihood- N.A. NO NO
Severity -
18 Cleaning, BIOLOGICAL - PFS Likelihood – M Dirt, uncleaned Thorough cleaning and NO
Sanitation Microbial growth Severity - H surfaces, solid wastes disinfection of the
Disinfection, harbour pest which processing area, followed
Pest Control and leads to contamination, by disposal of waste and
Waste thus reducing shelf life. periodic pest control
Managemet in
the Processing
Area
Page : 53 :
-1 -2 -3 -4 5 6 7 8
enhanced at this
step
18 Cleaning, CHEMICAL - PFS Likelihood – M The tea will become Thorough washing with No
Sanitation Presence of Severity - H toxic, making it unfit for running water is done
Disinfection, Washing human consumption. before using sanitizer /
Pest Control and Chemicals / Disinfectant.
Waste detergents
Managemet in
the Processing
Area
PHYSICAL - Nil Nil Likelihood – N.A NO NO

Severity -
QUALITY - Nil Nil Likelihood- N.A. NO
Severity -
19 Cleanliness and Biological - Growth PFS Likelihood – M Left over of Tea leaves, Every tool, equipment, NO
maintenance of of bacterial pathogens Severity -H Dust, Fibres or extracts machinery & Food Contact
equipments, will contaminate the end Surfaces are cleaned before
tools product. and after every use.
machineries &
Food
Contact
Surfaces
CHEMICAL - Nil Likelihood – N.A No No
Nil Severity -
PHYSICAL - Nil Nil Likelihood – N.A NO NO
Severity -
QUALITY Nil Nil Likelihood- N.A. NO NO
Severity -
Page : 54 :
-1 -2 -3 -4 5 6 7 8
enhanced at this
step
20 Personnel BIOLOGICAL - PFS Likelihood – H Multiplication of micro- Proper personnal Hygiene, No

Hygeine, Disease Microbial growth due Severity - H organisms occur due to Disease Control, Health
Control, Health to cross transmission of diseases, check ups and check on
check ups, contamination. ill- health, poor or Personal habits are
Personal habits. unhygienic personnel maintained.
habits. This cross
contamination affects the
tea.
CHEMICAL Nil Likelihood – N.A NO NO

Nil Severity -
PHYSICAL Nil Nil Likelihood – N.A NO NO
Severity -
QUALITY Nil Likelihood – N.A NO NO
Nil Severity –
21 Control on the Biological - Nil PFS Likelihood - M Nil Nil NO

Bought Leaf - the Severity -
Preceeding link in H
Food Chain CHEMICAL - PFS Likelihood – M Harmful for human The Bought Leaf Suppliers Control Point -7
Presence of Pesticide Severity -H consumption, can cause are not supposed to use the
residues & heavy sickness banned Chemicals & use
metals pesticides within the
permissible limits only.
They are also supposed to
maintain, spraying and
plucking gap.
PHYSICAL Nil Likelihood- M N.A N.A NO

Nil Severity –H
QUALITY Nil Nil Likelihood- N.A N.A NO

Severity –
Doc No. : ATE/SOP/17
LUXMI TEA STANDARD OPERATING PROCEDURES Rev. No. : 0
COMPANY Issue No. 1
PVT. LTD. In- House Calibration of Thermometers Page No. : 21
Scope : Practice of Calibrating all thermometers, In- house with a Master Thermometer calibrated by
a Recognised Institution.
Responsibility : Assistant Manager - Factory

Master Thermometer Number
Procedure :
1. Kiron Standard Calibrated Meter 0 - 100 degrees centigrade, Instrument No. of
ADDABARIE TEA ESTATE tested by M/s. Maity Meters for Works Accuracy, has been taken as a
Master Reference Instrument, used for calibrating other Thermometers for accuracy.
2. The Master thermometer alongwith all other thermometers are placed in a vessel with sufficient water, so
that the probe / stem of the thermometers are completely immersed.
3. The water is boiled alongwith the thermometers and the rise in temperature in each thermometer is
recorded in relation to the Master Thermometer.
4. The correct thermometers will register equal rise in temperature with the master thermometer.
5. The Thermometers showing incorrect readings are send for repair or re- calibration.
6. Record of In - house Calibration of all thermometers are maintained.
Record :
Calibration Records
Prepared By : Approved & Released By -

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Internal Audit Page No. : 22
a. Purpose : Internal Audits judge whether the Requirements for a ISO 22000 - based Food Safety System
conforms with the planned arrangements of the Organization or not and scrutinises how effectively the
System is implemented and maintained.
b. Methods : The team members plan an internal audit scheme, taking into consideration the status and
importance of the processes and areas to be audited, as well as results of the previous audits. An Audit
Schedule mentioning scope and detail the frequency and how audits are to be
conducted to verify the effectiveness of the Food Safety Plan is prepared.
Selection of auditors and conduct of audits ensure objectivity and impartiality of the audit process.Auditors
cannot audit their own area of work.
Personnels conducting Internal Audits are trained on internal auditing procedures. Where possible
auditors are independent of the area or function being audited. They are to be aware of the entire
documents and procedures.
c. Tasks and responsibilities : The Food Safety Team Leader is responsible for scheduling and conducting
Internal Audits. Responsibilities for conducting internal audits is extended to respective personnel on
verifying the effectiveness of the Food Quality Plan.
The following areas are audited by certified internal auditiors independent of the function to be audited.
1. The Factory Process & Production
2. The Factory Sanitation & Cleanliness is audited by the Medical Officer .
3. The Stores is audited by the Manager .
4. The Garden is audited by the Assistant Manager - Factory.
5. The following areas are audited by certified internal auditiors independent of the function to be audited.
d. Frequency : Internal Audits are conducted once in twelve months.
e. Records : On basis of the Internal Audits conducted, Audit Report mentioning
the Non - Conformances and the Audit Summary mentioning the corrective
actions taken against the Non-Conformances arisen from the result of the Internal Audits are prepared.
The Food Safety Team Leader ensures that the corrective actions are taken without undue delay to
eliminate detected non - conformities and their causes.
Follow - up activities include verification of the actions taken and the reportin of the Verification results.
Internal Audit File has filing of the following Documents :

1. Internal Audit Schedule -
2. Internal Audit Report -
3. Internal Audit Summary -

ASSISTANT MANAGER
Date : June, 2021.

COMPANY Issue No. 1
PVT. LTD. Management Reiew Meeting Page No. : 23
5.8.1 General :
ADDABARIE TEA ESTATE have implemented a procedure for reviewing the Food Safety Management System,
once in twelve months to ensure continuing suitability, adequacy and effectiveness. The review evaluates the
assessing opportunities for improvement and the need for change to the Food Safety Management System,
including the product safety, policy and objectives.
The review provides evidence of the commitment to improve the FSMS and its performance.
The effectiveness of the Pre - Requisite Programs and other controls implemented to assure food
safety are also documented.
The Food Safety Team Leader is responsible for completing reviews of the FSMS and the Food Safety Plan,
over the Review Meetings conducted once in every six months.
A Food Safety Plan is reviewed when a major change to a product formulation, its process, process controls
or any other factor that has direct impact on food safety and quality arise.
Major changes to a Food Safety Plan that has direct impact on food safety is developed, validated, verified.
All reviews and changes to the FSMS and the Food Safety Plan is documented under Records of Review
Meetings.
9.3.2 Review Input :
The input to the Management Review Meetings include the following Agenda :-
a.) The status of action from previous Management Review.
b.) Changes in External and Internal Issues that are relevant to the FSMS including changes in the
organisation and its context (see 4.1)..
c.) information on the performance and the effectiveness of the FSMS, including trends in:
1) result(s) of system updating activities (see 4.4 and 10.3);
2) monitoring and measurement results;
3) analysis of the results of verification activities related to PRPs and the hazard control plan (see 8.8.2);
4) nonconformities and corrective actions;
5) audit results (internal and external);
6) inspections (e.g. regulatory, customer);
7) the performance of external providers;
8) the review of risks and opportunities and of the effectiveness of actions taken to address them (see 6.1);
9) the extent to which objectives of the FSMS have been met;
d) the adequacy of resources;
e) any emergency situation, incident (see 8.4.2) or withdrawal/recall (see 8.9.5) that occurred;
f) relevant information obtained through external (see 7.4.2) and internal (see 7.4.3) communication,
including requests and complaints from interested parties;
g) opportunities for continual improvement.
The data shall be presented in a manner that enables top management to relate the
information to stated objectives of the FSMS.
ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Management Reiew Meeting Page No. : 24
9.3.3 Review Output :
The outputs of the management review shall include:
a.) decisions and actions related to continual improvement opportunities;.

b.) any need for updates and changes to the FSMS, including resource needs and revision of the
food safety policy and objectives of the FSMS.
The organization shall retain documented information as evidence of the results of

management reviews.
ASSISTANT MANAGER
Date : June, 2021.

COMPANY Issue No. 1
PVT. LTD. Corrective & Preventive Actions Page No. : 25
7.10.2 Corrective actions : - Corrective actions are initiated by responsible authorities having sufficient
knowledge and experience on monitoring of operational PRP's and CCP's. When there is a lack of
conformity with operational PRP's or when critical limits of designated CCP's exceed, Corrective Actions
are initiated.
Against each Critical Control Point, corrective actions are taken when action limit value or critical limit is
exceeded. The procedure includes the process to investigate the cause of the deviation. A documented
justification for the corrective action is available in the Process Control Plan / Food Safety Plan, which
which includes the reponsibilities and authorities of the personnel involved. The actions to be taken is
established in advance.The team evaluates the causes of deviation and decides which additional preventive
actions are to be taken.
The effectiveness of the corrective actions, for both the process and product is evaluated.
The products resulting from the process while the critical limit has been exceeded, is treated as non-
conforming products. The corrective actions with respect to the product, include :
CCP 1 - If Laboratory Test Reports show that the teas are having content of pesticides and heavy metals
more than the allowable percentage, such teas are outrightly rejected.
Responsibility : Food Safety Team Member (Assistant Manager - Factory).
CCP 2 - After Drying, if the moisture content in tea is found more than 3.5 % , then that tea is sent
for gapping.
Responsibility : Assistant Manager - Factory.
CCP 3 - Teas if found having too much content of nails, ferrous particles and foreign alien materials, are
passed through high power magnets again, before final packing.
Responsibility : Assistant Manager - Factory.
When critical limits for CQP's deviate, corrective actions are taken as mentioned in the Food Safety Plan.
In case of any non-conformity / deviation is noticed at any stage of production or operation, then
Corrective Actions are immediately implemented, to ensure that such noted deviations do not recur.
Appropriate actions are taken to identify and eliminate the cause of the detected nonconformities, and to
bring the process or system back into control after the non - conformity is encountered, inorder to
prevent recurrence.
Necessary Corrective Actions are taken on : -
a.) reviewing non - conformities arisen from Customer Complaints, Internal Audits and Review Meetings.
b.) reviewing trends in monitoring results indicating development towards loss of control.
c.) on determining the causes of non - conformities.

d.) on evaluating the need for action to ensure that non - conformities do not recur.
e.) on determining and implementing the actions needed.

The Corrective Actions taken are recorded, reviewed and ensured that they
are effective.

ASSISTANT MANAGER
Date : June, 2021.

COMPANY Issue No. 1
PVT. LTD. Document & Data Procedure Page No. : 26
4.2.1 General
The Documentation structure of the Food Safety Management System includes the following :-
a.) A documented statements of a Food Safety Policy with its related objectives as required under Clause
No. 5.2.
b.)The Documented Procedures ( SOP) and its relevent records as required by this International Standard
are addressed
c.) The Documents required to ensure the effective development, implementation and updating of the FSMS
are mentioned.
4.2.2 Control of Documents

Documents and Records required by the Food Safety Management System are controlled as mentioned
The controls ensure that all proposed changes are reviewed prior to implementation to determine their
effect on food safety and their impact on the food safety management system.
All documented procedures are established to define the controls as :-

a.) Prior to release of an issue of any document, the same is approved for adequacy by the Factory
Assistant Manager and released by the Manager
b.) Review, updation and re-approve of documents are also done by the Assistant Manager on consultation
with the Manager of the Tea Estate.
c.) With every amendment or changes done in a document the Revision No. changes. Having attained ten
revisions i.e. with Revision No. 10 , the Issue No. of the Document changes.
The personnel who approves the document, signs on the amendment list, against the amendments done.
d.) At present Revision No. 0 and Issue No. 1 is in use. Amendment done at any page in any document
will be listed out in the Amendment List of the concerned Document for easy reference.
e.) All documents are legible and readily identifiable. The renewed amended documents are filed, controlled
and retained for a minimum of 5 years.
f.) All relevant documents of external origin are identified and their distribution controlled, in the manner as :
The Master set of every Document stamped in Red is kept with the Manager.
One set of Controlled Document stamped in Blue is kept with the Assistant Manager - Factory.
Another set of Controlled Document stamped in Blue is kept with the Manager - BTE
g.)To prevent unintended use of obsolete documents the same is immediately stamped by stamping
OBSOLETE' stamp. To ensure that they are suitably identified, they are retained separately for any future
reference / purpose.
ASSISTANT MANAGER
Date : June, 2021.

COMPANY Issue No. 1
PVT. LTD. Communication Page No. : 27
5.6.1 External Communication
a. Intended use as
already mentioned.
b. Agreement of Carriage / Fertilizers / Chemical Suppliers / Materials & Spares suppliers
parties have been informed.

the parties have been informed.
d. Tea Board & TRA Notifications
e. Food Safety Standard Authority of India Regulation Act.
5.6.2 Internal Communication
a. Food safety Team leader should be informed of the following if there is any change.
i. Documents should be changed with change of policy / Product

ii Statutory / Regulatory changes
b. Green tea leaf is the raw material
c. All instructions are to be documented.
d. Review meetings and documentation

ASSISTANT MANAGER
Date : June, 2021.
LUXMI TEA COMPANY PRIVATE LIMITED
SOP
ADDABARIE TEA ESTATE
Doc No. : ATESOP/01

COMPANY Issue No. 1
PVT. LTD. LIST OF CONTENTS Page No. : 1
Document No. Titles Page Nos.
ATE-SOP/01 List of Contents 1

ATE/SOP/02 List of Amendments 2
ATE/SOP/03 Receiving 3
ATE/SOP/04 Withering 4&5
ATE/SOP/05 Rolling and Cutting of CTC Teas 6
ATE/SOP/06 Fermenting 7&8
ATE/SOP/07 Drying 9
ATE/SOP/08 Sorting and Grading of CTC Teas 10 to 11
ATE/SOP/09 Packing 12 to 13
ATE/SOP/10 Moisture Testing 14
ATE/SOP/11 Storage 15
ATE/SOP/12 Despatch 16
ATE/SOP/13 Product Identification 17
ATE/SOP/14 Product Traceability 18
ATE/SOP/15 Product Recall 19
ATE/SOP/16 Visitor's Policy 20
ATE/SOP/17 In-house Calibration of Thermometers 21
ATE/SOP/18 Internal Audit 22
ATE/SOP/19 Management Review Meeting 23 to 24
ATESOP/20 Corrective & Preventive Action 25
ATE/SOP/21 Documents & Data Procedure 26
ATE/SOP/22 Communications 27

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. LIST OF AMENDMENTS Page No. : 2
Document No. / Changes made Rev. No. Date

Page No.

ASSISTANT MANAGER
Date : June, 2021.
Doc No. : ATESOP/03
COMPANY Issue No. 1
PVT. LTD. RECEIVING Page No. : 3
Scope : To bring in garden fresh green leaves from the Gardens as fast as possible after plucking , to
avoid leaf damage.
Responsibility : Asst Manager - Field & Asst Manager Factory
Procedure :
1. Freshly plucked tea leaves are brought to the factory as fast as possible for spreading on the trough.
2. To avoid leaf damage, weighments are done thrice a day so that pluckers should avoid compactness
and braising.Compression of leaves in the baskets is harmful as it generates excessive heat and starts
fermentation before the leaves arrive factory.Continuous inspection is done to check that.
3. Leaves waiting for transportation to the factory, should not be exposed to the sun.Contamination with
foreign matter to be avoided.
4. Temperature more than 49 degree centigrade, breaks down the cell structure of the leaf, thus comm-
encing fermentation - giving rise to bacteria formation. So maximum of 18 kgs to be filled in a
basket.
5. From the Divisions of the Estate, the freshly plucked leaves are brought to the Factory by Tractor - Trailers.
Endeavours are made for carrying undamaged leaves to the Factory in cool condition even on the
heaviest of days.Once the tractor-trailer is filled up , the same is driven to the factory with minimum of
delay.Where road surface is not smooth, due to sudden jolts to the trailer, considerable bruising of
leaves takes place.
6. Green leaf carrying Tractor-Trailer on entering into the factory premises comes to the Weigh Bridge.
Loaded Trailer is weighed, Tare wt. and Net wt. recorded. Weighment Record contains time of collection,
quantity in kgs, time of arrival, from which Garden,Division, Challan no., Date , Section no., Trailor number,
Prune / Unprune
7. A check on the gap between Spraying and Plucking is also maintained in the Register, after tallying
with the approved list of chemicals and pesticides used in the gardens.
8. Any deviation in leaf or weighment, is brought to the notice of the Deputy Manager / Assistant Manager. The
trailor comes out of the Weigh Bridge immediately and necessary action is taken.
9. The Green leaves are unloaded under the covered shade, for immediate transfer to the withering
troughs. Leaf received in damaged condition are put on the trough using cool air to reduce its warmth.
Record : Weighment Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. WITHERING Page No. : 4
Scope: To extract out excess moisture and condition the leaf for further processing.
Responsibility : Asst Manager - Field & Asst Manager Factory
Procedure :
Green leaves are spread evenly throughout the length of the troughs so that individual shoots are
separate from one another.During spreading no labour is allowed to walk on the leaves. Leaves are
handled with care to avoid damage.
1. The upward airflow of not less than 35 cfm/sq ft at 0.5 WG.,allows conditioned air to pass up or down the troughs
through the leaf bed .
2. Axial flow fans are used in troughs
3. Once leaves are spread, hot and cold air is blown through the leaves for 12 to 16 hours
Cold air has a normal ambience while hot air is blown at a temperature of 82 to 100 degrees
Farenheit.The air speed should not be allowed to lift the leaf from the bed of the trough.
4. The temperature of the inlet air should be high enough to bring about a Hygrometric Difference
(H.D) of 4 to 7 degress Fahrenheit.
5. Leaf damage on the withering trough is accelearted by indiscriminate use of hot air. If there is any heat
development within the leaf, the fans are restarted to apply cold air.
6. Lowest possible temperature is used to bring down the moisture level. In case of very wet leaves, the
surface moisture is driven off by using inlet air with an H.D of upto 15 degrees Fahrenheit for a very
short time. In no circumstances should inlet air in excess of 100 degrees fahrenheit is to be used. When
using heated air to drive off high surface moisture, the process is more carefully supervised.
7. Ambient air is used for about 30 minutes in order to bring down the leaf temperature before lifting
the withered leaf
8. For manufacturing of CTC,extraction , withering to be done at 69 % to 72 %, 66% to 68%

Moisture contents respectively.

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. WITHERING Page No. : 5
Withering involves physical and chemical wither.Through physical wither moisture is removed, elasticity
of the leaves increases, which helps in size reduction. Leaf becomes flaccid and assumes velvetty
appearance. Physical wither lasts for 3 to 4 hours.
Through chemical wither chlorophyll (green) breaks down to pheophytin (black) & pheophorbide (brown)
The greenish colour of the shoots reduces slowly as withering progresses. The larger molecules of
protein breakdown to smaller ones that results in the increase of amino acids and flavour compounds.
The caffeine content also increases which brings stimulation in tea. Chemical wither lasts for 12 to 16
hours.
Type of wither Extent of Theaflavins (TF) / Thearubigin (TR) Liquor
CTC
Unwithered or under More TF, less TR Bright and brisk , less body.
withered
Optimum withered Balance of TF & TR Less bright, brisk but good body.
Over withered Less TF , more TR Flavoury, flat insipid.
Record : Withering Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. ROLLING AND CUTTING Page No. : 6
OF CTC Teas
Scope : Withered leaves are cleaned,preconditioned , crushed, torn and curled in this process.
Procedure :
1. The withered leaf coming into the factory on the monorail is passed through a regulated feed unit
wherein the quantum of leaf passing through the CTC is controlled and also the leaf is sifted to remove
extraneous matter. Magnets are also provided to remove iron impurities.
2. The cleaned withered leaves are passed through a Rotovane Machine for pre conditioning to make the
leaf small and soft to facilitate passage in the CTC mchines.
A 15"diameter Rotovane can process 900 - 980 kgs of processed leaf per hour. Speed varies from 26 to
28 r.p.m .This machine can process 35.0 kgs of withered leaf per RPM / hour.
This matches with the output of 36" CTC machine. Overfeeding of the rotorvane will result in pile up of the
leaf in front of the spreaderof the first CTC cut .
3. The Iris Plate attached to the machine is adjusted as per the withered leaf , so that much of juice is
not expressed. The Iris Plate allows either free or restricted flow of leaves as per the need.
The feed must be thick enough to keep the barrel full at all times so as to continously sustain a high
pressure on the leaf.
4. The processed tea is carried by a Conveyor Belt having Bar magnets, to CTC Machine and goes for
1st, 2nd & 3rd cut.
5. The CTC cut is inspected at regular intervals. Records are maintained of this check giving the time
the check was made, details of any adjustment made and the initials of the person who is on check.
6. The leaf deposits from the CTC machines and conveyor are brushed off periodically..The
leaf deposits from the roller or roller cover are frequently brushed off. To control bacterial infection, the
CTC machines are sanitised using Steam Sterilization after every four hours of manufacture.
7. The Rotary pass of the leaf after its final CTC cuts is the last stage of the CTC process
This gives the tea the black, shotty, fibre free grainy style.
Record : Rolling & Cutting Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. FERMENTING Page No. : 7
Scope : During fermentation, the TF ( Theaflavion) gets converted to TR ( Thearubigin), the presence
of both in proper proportion gives a good cup quality.
Procedure :
1. This is carried out on Continous mooving Trays fitted in Monorail
2. The rate at which the various changes in the fermenting proceed depends on various factors
like leaf wither, type of processing and the temperature.
3. The Humidifiers of the fermenting area are started 1/2 an hour before the mal reaches the room. In
the fermenting area, the humidification used to maintain the hygrometric difference is between 1 to 2
degrees fahrenheit , i.e in between wet and dry bulb meters at all times.
3. The TF content is highest in unwithered leaf it decreases with the hardness of wither. TR on the other
hand is lowest in kutcha leaf but starts increasing along with the increase in withered CTC. The liquor
characterestics as affected by different withers are depicted as follows :
i. No Wither : High TF (+) Brightness / Briskness

Low TR (-) Strength / Body
ii. Normal Wither : Less TF (-) Brightness / Briskness
(70 - 75%) (+) Strength / Body
iii. Hard Wither : Lesser TF (-) Bright ( Dull ) / Briskness
(Below 60 %) Lesser TR (+) Strength / Body ( Thin )
iv. Very Hard Wither : High TR (+) Strength / Body
Theaflavins (TF) are yellow bodies which impart brightness, briskness and quality in tea and additional
or prolonged fermentation leads to formation of TR (Thearubigin).
Thearubigin (TR) are red and brown bodies with fanning properties, which impart body and strength to
the cup.
4. Higher the temperature, lower will be the fermenting time. Lower the temperature, higher is the Fermenting time.
Fermentation of tea is done as per the Chart followed internally.
5. The mal is lifted in Aluminium Gumlas placed in hangers of the monorail for transporting it to the
Drying Section.These gumlas are emptied manually over the conveyor belt feeding the driers. The
empty containers are placed on the hangers to be carried upto the fermenting room for re-filling with the
fermented teas. Approximately, 6 to 7 kgs of fermented tea is loaded into one gumla and placed on the
alternate hangers of the monorail.
7. The temperature of the processed leaf is recorded in every module of the CFM (Continuous fermenting Machine)
to optimise the liquor charecteristics
8. Any type of Bacterial infection is detrimental to the fermenting process. Regular monitoring and record
is maintained.
Record : Fermentation Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. FERMENTING Page No. : 8
The following Chart is followed in the Rolling, Cutting / Sifting and Fermenting Section, applicable for
CTC teas.
Temperature Fermenting Time
70 F 1.40 Minutes
72 F 1.35 Minutes
74 F 1.30 Minutes
76 F 1.25 Minutes
78 F 1.20 Minutes
80 F 1.15 Minutes
82 F 1.10 Minutes
86 F 1.00 Hour
88 F 55 Minutes
N.B.
10 minutes has been calculated for Mono Rail from Fermenting Room to Drier Section.
At this stage, through enzymatic oxidation, polyphenols are formed, the compound that furnish the
characteristic taste of black tea.Withered leaves lose their green colour and grassy odour - acquire a cop-
pery red shade and aroma of tea. Caffeine formation also takes place.The oxidised polyphenols cause
degradation of amino acids to aldehydes.Carotenes become beta-ionene, alpha-ionene giving typical
tea flavour. Fatty acids also degrade to aldehydes, which are flavoury compounds. For fermentation
abundance of oxygen is required.
Extent of fermentation Extent of Theaflavins / Thearubigin Tea Quality
Under fermentation Less Theaflavins , less thearubigin Less bright, thin liquor with flavour
Proper fermentation Theaflavins : Thearubigin = 1 : 10 Balanced liquor, bright, brisk

body.
Over fermentation Less Theaflavins , more thearubigin Dull flat tase , heavy liquor.

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. DRYING Page No. : 9
Scope : The moisture content level in black tea is brought down to be within 3.5 %.
Procedure :
1. The hot air passing through tea dryers has 4 functions

a. to transfer heat
b. to evacuate moisture
c. to cause diffusion
d. suspend and convey the tea particle through the dryer
2. Dryer is a combination of Conventional Tray & a fluid Bed dryer. The Tea in the first circuit travels on
trays for a period of 3 to 6 minuites depending on the pulley. In the 2nd Circuit, the tea is fluidised by velocity of air
and forward movement of trays. The 2nd circuit takes roughly 17- 19 minutes.
Dryer is a continuous Tray dryer with a throughput time of 23 to 26 mins. The tea is fed on the cold feed
trays and travels through four continuous circuits.
3. Underfeeding the dryer gives low capacity and high fuel consumption ,undesirable fly off and high or overfired
teas and overfeeding will give inferior quality, underfired teas .
4. The trays of the driers are brushed to clean the leaf particles that are caught in tray perforation. If
blocked, the airflow will automatically become restricted. All air leakages are sealed properly to have
smooth circulation of hot air. The spreaders and scrapers are checked properly to be in good working
condition. The air seals between the trays are also checked to be working freely.
5. Tea is placed on perforated moving trays through which the hot air escapes,in the process dries the tea.
The spread of leaves in the dryer is ensured to be even on all the running trays.The inlet thermometer
is checked before use. The dry air should be free from any taint or colour. Tea leaves bounces on the
tray, keeps moving and pushing inside the dryer, thus drying the tea.
6. The moisture in the fermented leaf to be fired, will vary according to the degree of wither.
Record : Drying Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. SORTING AND GRADING Page No. : 10
Of CTC Teas
Scope : To segregate the bulk tea into different grades as per standard sizes and remove fibre,fluff,
ferrous and foreign particles.
Procedure :
1. The black tea from the drier is carried through the Conveyor Belt to the Ball Separator fited with a No. 6 mesh
The Ball mal goes to Ball Breaker or Mini CTC to roll and crush, collected in a Weight Box, graded, refired
and mixed with the main bulk.
2. The black tea from the the ball separator is carried by another Conveyor Belt to the Batch Weighing machine
of10 kgs.,
3. The weighed tea goes to the hoppers connected with magnet of the Fibrex Machines through another
conveyor belt.
4. Tea from the two Fibrex Machines is lifted by bucket elevators to the two GEM Vibro Screen Sorters
where different sizes of meshes are fitted which seperates different grades of tea.
5. The primary grades are collected in seperate gradewise storage bin which are then taken to another fibrex
machine for final cleaning.
6. The Side mals are carried through the Conveyor Belt to the Secondary Sorting Machine, for secondary
grades like BP1,PF1 & D1.
7. S.S Wire meshes of proper size / tight frame are used. The meshes are cleared at every 2 to 3
hours for any clogging.The felt of all the PVC rollers are checked, so that the electro- static charge is
produced to lift free floating fibres.The felt and the magnets are cleaned at an interval of every 2 to 3 hrs
Following are the different sizes of meshes used for grading CTC : -
BPS Above 8
BOP Below 8 and above 10
BOPsm Below 10 and above 12
BP Below 12 and above 20
PF Below 20 and above 24
PD Below 24 and above 30
Dust Below 30 and above 40
8. The graded CTC teas are sent for further cleaning to extract out any free floating fibre by the help of
Java Tunnel also known as the High density Fibre Seperator, which also seperates foreign particles.
9. The fibre so extracted is sent to the pulverizer for milling.
10. The cleaned graded teas are ready for packing thrrough the Packing Hopper Machines into various
packages.
Record : Sorting and Grading Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. SORTING AND GRADING Page No. : 11
Glass Policy : Sufficient precautionary measures are being taken to prevent glass pieces from
mingling with tea leaves; i.) by not allowing the ladies at work to put on glass bangles.
ii.) by taping off of the glass windows by cellotape, at the processing areas to prevent breakage of
glass pieces to mingle with tea leaves.
iii.) No individual working directly with tea leaves should use any type of glass object at the processing
area.
iv.) At the Sorting and Grading stage, the tea is passed through different sizes of meshes (as mention-
ed in the earlier page) to detect and arrest the glass particles.
Wood Policy : Sufficient precautionary measures are being taken to prevent wood pieces from
mingling with tea leaves. Also steps have been taken to prevent the wood used in the tea manufactur-
ing process to be free from fungus / moss or moisture. The precautionary measures taken are : -
i.)The wooden battens on which tea packages are stored are fumigated to avoid gathering of moisture.
ii.) Wooden splinters found in tea are detected by passing the tea through different sizes of meshes
(as mentioned in the earlier page).
Jewellery Policy :
i.) No worker or staff is allowed to work in the Production Unit with Watches in hand and rings in fingers.
ii.) Lady workers are not allowed to put on bangles. If unavoidable, they can put a band round their wrist.
iii.) Wearing of any other type of ornaments is strictly restricted.
iv.) No worker or staff is allowed to carry coins in their pockets, as tea being a homogenoeus product, it
might get mingled up.
Knife Policy :
No knife is allowed inside the Factory premises by any individual.

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. PACKING Page No. : 12
Scope : The sorted and graded teas are packed in different packages as per the requirement.
Procedure :
1. Sorted and graded teas are stored on the Bulking Sheets made of canvas cotton, size 18 x 20 ft
approximately.When sufficient tea of one particular grade is collected, bulking & packing operation takes place.
2. The graded teas are passed through the Packing Hopper Machine fitted with magnets to arrest the
ferrous particles.
3. Packing is done in Paper sacks of full and half size weighed
by electronic weighing scale before and after filling with tea.
4. At the time of packing, samples are drawn for moisture testing. The moisture level is checked to be
within 3.5 % .
5. Packing Machine is used for export teas which gives uniform shape to the paper sacks.
The bags are filled to the optimum quantity and then sealed, stencilled and stacked.
The Packing details observed are as per customer specification or Head Office instruction.
Records : Moisture Testing, Packing and Storing Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. PACKING Page No. : 13
Suppliers Approval Programme for Packing Materials
The Sub- Contractors for the packaging materials are selected at Head Office.
The Packaging materials

Paper sacks, selection of which is done on inspecting their quality, production
facilities, factory infra-structure, on-time delivery, rejection percentage and price of the commodity etc.
The Sub-Contractors are chosen on evaluating their product knowledge. They are first asked to prepare
and produce samples which are checked and approved by the Purchase Department. The approved
samples are duly stamped and signed by the Purchase Department, at Office, counter- signed by the
Sub - Contractor and are retained at the factory. A list of all Approved Sub-Contractors is documented
and made handy for easy reference
When the commodities are supposed to have met the desired specifications / requirements, the
Purchase Department takes quotation from the Sub- Contractors, negotiates and finalises the deal on
issuing the Purchase Order which contains the details of the items ordered, quantity, rate, amount and
the date of delivery.
The Sub-Contractors while delivering the goods at the factory submits a copy of the Purchase Order,
which the Staff - in - charge tallies with the incoming goods. At the time of arrival of one particular
item, the same is tallied with the proto-type sample, checking the dimensions, specifications and the
finish. Goods if not found suitable are returned forthwith which are later replaced back. The quality of
the goods received are closely monitored and rejection percentage is calculated.
Evaluation of Sub- Contractors are worked out at the end of the year
Monetary adjustments are done on the bills at the Head Office.
All packaging materials that are directly in contact with tea are of Food Grade Standard approved by
BIS ( Bureau of Indian Standards).
Packaging materials that have direct impact on product safety are been inspected before use though
purchased from Approved Suppliers. All incoming packaging materials are checked by the Staff -in -
Charge of the factory and records maintained under Packing Material Check Register
At the Packing Section, the system of FIFI (First In First Out) is very widely practiced.

ASSISTANT MANAGER
Date : June, 2021.
LUXMI TEA STANDARD OPERATING PROCEDURES Issue No. 0
COMPANY Page No. : 1
PVT. LTD. MOISTURE TESTING Rev. No. : 14
Scope :
Detection of Moisture Content in tea which will prevent growth of mould, yeast and fungi.
Procedure :
1. Check on Moisture content is done by Kaybee Infra - Ray Moisture Meter. It is a scale with pan on
one side and a weight with ring chain tied on the other side.The balance is calibrated at equilibrium
with the chain set on "0" level on a slide marked from 0% to 10% in such a way that a given volume
of tea on the pan will balance the scale.Moving the chain on the slide will change the balance and the
degree of variation will be shown by the marks on the slide.
2. An Infra Ray Bulb is positioned on the top of the pan with given distance. A random sample of tea
with the given volume is put on the scale such that it is at equilibrium.
3. The bulb is put on for 5 minutes. It is the generally accepted time by which the tea put of the pan
will be fully dried and devoid of moisture in it.
4. With loss of moisture the tea in the pan will lose weight and the scale will be off balance.
5. The degree of off balance is measured by moving the chain on the slide up till the balance is at the
equilibrium again. Loss of weight ( i.e. moisture) will be the point on slide on which the scale is in
balance again. The moisture lost in the process is taken at the moisture content of tea.
6. If the reading is lesser than 3.5%, the moisture content is said to be within normal. If the reading is
more than 3.5%, the moisture content is said to be above normal, so the tea is sent for refiring.
Records :
Moisture Testing, Packing and Storing Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. STORAGE Page No. : 15
Scope : Storing tea in congenial environment brings good shelf life for tea.
Procedure :
1. The sealed , stencilled and marked packages are stacked as per Invoice Numbers, Lot Numbers on
wooden battens / iron rails covered with polythene sheet- 3'' above the floor, 1' away from the wall and upto a height
of 8 stacks maximum.
2. Only Black ink is used for stencilling, which is of food grade quality, purchased from approved source.
This is non- permeable and do not contaminate the tea packed inside
the packing material.
3. The Paper sacks are stacked in marked bays

as per the Invoice Nos.on wooden pallets or Battens or platforms.
4. The representative sample of all the Invoices are sent to the Head Office / Brokers and Buyers for
necessary action.
5. Upon receipt of the instruction from the Head office, the packages are despatched to the respective
destinations.
Record :

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. DESPATCH Page No. : 16
Scope : Despatch to be correctly done following Head Office instruction. Any deviation may call for
disaster.
Procedure :
1. Following the instructions from the Head Office, the packages are weighed randomly before despatch.
2. Any package found damaged or stained are replaced immediately before despatch.
3. Before despatch the lorries are inspected by the in- house excise clerks for any unwanted foreign
materials, water stains etc. to prevent contamination.
4. Lorries are weighed at the Weigh Bridge before loading.
5. Lorries with tarpauline on bottom and on top are only to to be used for protection against rain water.
6. At the time of Despatch, the details of the packages are mentioned on the challan and on the Register
the Vehicle No., the Transporters Name, Driver's Name and Signature and the date of Despatch is noted.
Record : Despatch Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Product ldentification Page No. : 17
The Organization ensures that all Finished Goods Packages are properly marked and clearly identified
to the Customers Specifications , if given any.
The system follows product marking & identification, which allows one to identify the product at any
point of transit i.e at Customer's / Transporter's / Auction Warehouse, Destination / Delivery Point ,etc.
once it is out from the factory gate. If anything goes wrong at any point of time with the product, the
same can be identified and required step taken.
Each package is identified by its Invoice No., Garden Name, Grade, Bag Serial No., Year of manufacture,
Gross Weight, Tare Weight, Nett Weight , Break sizeand the Organization's Name and Address.
All of these relevant product identification informations are noted in the Invoice cum Challan Form
With reference to the above Form, the following Registers can be checked to back track and identify
the date of packing, date of manufacturing, from which section of the estate was the tea procured
and the persons responsible for doing each job, etc.
Records Maintained :
Weighment Register
Withering Register
Rolling and Cutting Register
Drying Register
On - Line Monitoring Register
Despatch Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Product Traceability Page No. : 18
All Finished products are made traceable to the customer. The Company maintains traceability of the
product from the Origin of the Green Tea leaves upto Finished Consumer Packs - tea in Bulk form
packed in Paper sacks.
Since raw materials have direct impact on the finished products safety and Quality, the cultivation,
pruning, pesticide spraying, plucking of green tea leaves are taken care and collection recorded to
make it traceable throughout the process upto the Finished Product and to the Customer.
The Assistant Manager - Factory is responsible for implementing and maintaining the product trace
system.
The methods used to trace finished product to a customer is outlined as below :-
1. The incoming Green Tea leaves are entered in the Weighment Register
wherein from which section of the estate and when the tea is being collected is mentioned.
2. During the manufacturing process, the checks on tea is maintained under Monitoring Record for tea
under Register
3. All Packing Materials are entered, checked and noted in the Packing Material Check Register
, against the Sub-Contractors Challan.
4. Each Bulk Pack is identified by a Bag Serial Number and the Year of Manufacture.The Invoice No. can
be traced back from the date of packing to the date of receipt of packing materials.
5. The record for product despatch and destination is maintained in the Invoice cum Challan, Form
6. All relevant records related to product traceability are maintained in the following Registers :
Weighment Register
Withering Register
Rolling and Cutting Register
Drying Register
On - Line Monitoring Register
Despatch Register
7. Where any reworking of the product is performed, the above product trace system ensures that the
traceability will be performed.

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Product Recall Page No. : 19
Procedure for Product Recall :

A documented procedure on Product Recall is developed within the Organization, in which the respon-
sibilities, management and protocols to be implemented are clearly described. If need be, as per the
management's protocol, involving the concerned personnels of the organization, products already desp-
atched from the factory or delivered at Buyer's destination may for some reason have to be called back.
The System of Product Recall is documented as follows :

1. Product despatched out of factory premises but not shipped out, if left with any identification /
shipping mark incomplete is called back by the Assistant Manager - Factory in consultation with
the Managers
2. After Despatch, Test Report from Laboratory received on the packed tea, not in conformity with
Buyers requirement / specifications, can be called back for rectification by the Deputy General Manager / Senior
Managers / Managers if instructed by the Head Office, before the Buyer rejects the entire consignment.
3. Drawn sample of despatched tea, observed to have acquired any public threat , which was not notic-
ed earlier, can be called back immediately on an urgent basis, before going into the hands of any
consumer.
4. Any product after reaching to the buyer's destination, if fetches complaint from the Buyer, the same
is immediately noted in the Customer Complaint Register and necessary steps undertaken.
i.) If complained of short quantity or minor packing problem or damages, can be settled down over
negotiating the claim that they have lodged.
ii.) But if he complains of any Quality / Product Specification mis- match, then Inspection Agencies at
the destination country is assigned to draw the sample and test at their laboratory on the nonconformities
pointed out.
iii.) If Test report is O.K, acknowledged and approved by the Buyer, the Claim stands null and void.
If Test report is negative, the Organization has to either pay penalty on settling the claim or take back
Consignment from the buyer.
iv.) If found alternate Buyer at the same destination to take the same cargo, the G.M - Marketing in
consultation with the Executive Director decides, meets, negotiates to sell off the consignment or else
alternatively calls back.
v.) The Product recalled is tested and verified at the Originating countries Laboratory and records maintained.
It is ensured that the nature of the incident is notified to the customers and other essential bodies in a
timely manner.
The Product Recall procedure is reviewed, tested and verified at least once in an year. Records of all
product recalls, reviews and results of testing the product recall system is maintained in the Register

ASSISTANT MANAGER
Date : June, 2021.
COMPANY Issue No. 1
PVT. LTD. Visitor's Policy Page No. : 20
All Visitor's entering into the Factory of ASSAM GARDEN, are to strictly follow the Visitor's Policy as
mentioned below : -
They have to adhere to the basic personal hygeine provisions and put on protective apparel before entering
into the Processing and Handling Areas.
VISITOR' S POLICY
1. All Visitor's entering into the Factory Premises have to put in his Name, Company's Name, Purpose
of Visit and declare that he is not suffering from any contagious disease in the Visitor's Register.
2. All Visitor's who intend to enter into the Processing Area are to remove their outside shoes and put
on the foot ware provided by the Office of the Factory.
3. They are requested to put on the Apron on and over their dresses and caps covering the hair, as
provided.
4. They have to pass through the Hand and Feet Wash Station, washing their hands with soap and
then sanitising the same with Potassium Permaganate solution.
5. Hands are to be totally dried up using a towel, before handling tea.
6. No Visitor is allowed to smoke or eat or spit in the Processing Area.
7. Visitor's having cough and cold are requested to use mask at the Processing Area.
8. No visitor is allowed to move around the warehouse premises without any official permission.
General Manager

ASSISTANT MANAGER
Date : June, 2021.

Tea Estate SOP

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FOOD SAFETY MANUAL

M/S DHUNSERI TEA & INDUSTRIES LIMITED

DILLI TEA ESTATE

DHUNSERI TEA & INDUSTRIES Doc No. : DLI-FSM-001

Clause No. Titles Document No. Page Nos.

- List of Contents DLI-FSM-001 1 to 2

4 Food Safety Management System DLI-FSM-008

5 Management Responsibility DLI-FSM-009

6 Resource Management DLI-FSM-010

7 Planning and Realization of Safe Products DLI-FSM-011

7.3 Preliminary steps to enable hazard analysis DLI-FSM-012 30

Doc No. : NHR-FSM-001

Clause No. Titles Document No. Page Nos.

7.3.2 Food Safety Team DLI-FSM-012 30

AMALGAMATED Doc No. : NHR-FSM-002

The e mplo yee de ta ils are a s fo llo ws:

AMALGAMATED Doc No. : NHR-FSM-003

AMALGAMATED Doc No. : NHR-FSM-004

2. The HACCP Principles developed by the Codex Alimentarius Commission.

3. Periodic notifications from TOCKLAI, Tea Research Association of India.

4. Time to time Circulars from Tea Board of India.

5. Time to time Circulars from Ms Amalgamated Plantations Private Ltd. HO.

6 The requirements of Factory Act , 1948.

7. Circulars from Auction centers at Guwahati and Kolkata

8. Requirements and Principals of ISO 22000 : 2005

9. Latest Edition of PFA

AMALGAMATED Doc No. : NHR-FSM-005

APPL Amalgamated Plantations Private Limited

AMALGAMATED Doc No. : NHR-FSM-006

Document No. Changes made Pg No./Rev No. Date

AMALGAMATED Doc No. : NHR-FSM-007

C ontrol m eas ur e, s pe cific : A me asu re to co ntrol a CC P.

AMALGAMATED Doc No. : NHR-FSM-007

AMALGAMATED Doc No. : NHR-FSM-007

AMALGAMATED Doc No. : NHR-FSM-008

AMALGAMATED Doc No. : NHR-FSM-008

4.2.2 Control of Documents

All documented procedures are established to define the controls as :-

AMALGAMATED Doc No. : NHR-FSM-008

List of Documents are as follows : -

Document's Name Document No. Approved and Released By

Pre - Requisite NHR-SOP-001 to 060 , Pages 1 to 82 Anshu Shukla Bhargav Siddhanta

AMALGAMATED Doc No. : NHR-FSM-008

List of Registers maintained at factory are as follows : -

Register Nos. List of Registers Maintained By

AMALGAMATED Doc No. : NHR-FSM-008

List of Forms maintained at factory are as follows : -

Form Name Form No. Maintained By

Local Purchase Order Form NHR / F / 01 Stores Clerk

AMALGAMATED Doc No. : NHR-FSM-008

AMALGAMATED Doc No. : NHR-FSM-009

5.2 FOOD SAFETY POLICY

Executive Director - APPL

AMALGAMATED Doc No. : NHR-FSM-009

Measurable Objectives planned is mentioned below : -

Policy Measurable objectives Goals and Targets

Finished Tea Test reports Conform to the Norms

ISO 22000 Certification Certification by year 2009

Market share- Trend analysis -do-

5.3 Food Safety Management System Planning

AMALGAMATED Doc No. : NHR-FSM-009

5.4 Responsibility and Authority

Senior Manager Overall management of the estate which involves

AMALGAMATED Doc No. : NHR-FSM-009