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: HA-BOCA-002
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Guiding Principles:
• A comprehensive process flow diagram of UNAHCO, Inc.’s product realization stages.
• The flow diagram serves as the guiding basis of UNAHCO’s HACCP Team to evaluate the
possible occurrence, increase, or introduction of product safety hazards.
• UNAHCO’s process flow is a straight flow that prevents cross-contamination and depicts
the following:
o the sequence and interaction of all steps in the operation
o Where raw materials, ingredients, and intermediate products enter the flow
o Where end products, intermediate products, by-products, and waste are released
or removed

Reference Document: Work Procedure (PR-BOCAMF-001)

ON-SITE VERIFICATION OF THE PROCESS FLOW DIAGRAM

Reference Document: Records of verified flow diagrams and process flow narrative
Guiding Principles:
• The HACCP team conducts on-site verification of the accuracy and suitability of
documented flow diagrams at least on an annual basis or as deemed necessary
• Relevant changes in the process (refer to factors that trigger HACCP review and updating)
requires the conduct of re-verification and updating of the process flow
• Verified diagrams are maintained as records

INTRODUCTION
UNAHCO, Inc. produces animal feeds, i.e., swine, poultry, game fowl, quail and domestic animal’s food for
the commercial feed and Pet food market. Located at 0136 Gov. F. Halili Ave, Barangay Turo, Bocaue,
Bulacan. It is a company owned plant built in 1995 and supplied by well-known feed mill and extruder
equipment manufacturers from Europe and Italy, known as Ottevanger, Buhler, La Meccanica. Bocaue
plant operates 24 hours with 45 tons per hour (TPH) capacity.

The following are the processes related to Feed Milling and Extruding in Bocaue Plant.

1a. LIQUID RAW MATERIALS (RM) RECEIVING

Incoming liquid RM deliveries are stationed in the designated parking area and are subject to RM inspection
and analysis. RM inspectors are to withdraw liquid samples from the top and bottom of the tanker truck and
subjected for physical inspection and laboratory analysis. Physical inspection includes color, odor, form,
and physical condition. Laboratory testing includes applicable chemical analysis. QA Released disposition
will be made when all results conform to the release criteria. Liquid RM’s in a container, such as mold
inhibitor liquid are to be loaded out to the Warehouse while Tanker trucks are moved to the Tank Farm for
load out or transferring liquid RM’s from other plant (coconut oil, RBD Coconut Oil and molasses).

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1b. PACKAGING MATERIALS (PM) RECEIVING

Incoming PM Deliveries are stationed in the designated parking area and are subject to PM inspection and
evaluation. PM inspectors are to withdraw packaging samples randomly and subjected for physical
inspection. QA Released disposition will be provided when all results conform to the release criteria. PMs
are stored in warehouse.

1c. BULK/BAGGED MACRO RAW MATERIALS (RM) RECEIVING

Incoming Bulk/Bagged RM deliveries are stationed in the designated parking area and are subject to RM
inspection and analysis. RM inspectors are to withdraw a composite sample from different bagged RMs
and subjected for physical inspection and laboratory analysis. Physical inspection includes color, odor, form,
and physical condition. Laboratory analysis includes proximate and/or applicable chemical analysis. QA
Released disposition will be provided when all results conform to the release criteria. Trucks containing
Bagged RM’s are transferred to the warehouse for load out. Trucks containing Bulk/Bagged RM’s, such as
Wheat and Yellow Corn, are moved to the Silo unloading area for shipment out. Yellow Corn, Hard Pollard,
and Rice Bran shall be inspected 100% during unloading from the truck.

1d. MICRO RAW MATERIALS (RM) RECEIVING

Incoming Micro RM deliveries are stationed in the designated parking area and subject to RM inspection
and analysis. RM inspectors are to withdraw a composite sample from different bagged Micro RM and
subjected for physical inspection and laboratory analysis. Physical inspection includes color, odor, form,
and physical evaluation. Laboratory analysis includes proximate and/or applicable chemical analysis. QA
Released disposition will be provided when all results conform to the release criteria. Micro RMs are then
transferred to the Warehouse.

2a. ADDITION OF ANTI OXIDANT IN COCO OIL

Incoming Coconut Oil deliveries are received in their designated tanks and anti-oxidant is added during
loading with the inclusion rate of 1 liter per ton. Anti – oxidant is added to prolong the shelf life and prevent
rancidity of the Coco Oil. Graduated beaker is used by trained personnel to ensure the correct dosage is
met.

2b. FUMIGATION

Incoming raw materials infested with weevils are rejected. In the event of critical or out of stock
situations, they may be reconsidered provided fumigation will be conducted to remove pest or crawling/
flying insects such as weevils. This is done by covering the material completely and filling the enclosed
area with gaseous fumigants to suffocate or poison the pests within.

2c. SILO LOADING (BULK MACRO RM)

Raw materials such as corn and wheat arriving in bulk trucks are weighed and then dumped in the Silo
loading pit, conveyed and elevated to the top opening of their designated silo storage.

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3a. LIQUID RAW MATERIALS (RM) STORAGE

Upon delivery or transfer of liquid RM’s into the main tanks, an anti - oxidant is added to liquid RM’s, Coconut
Oil inside the tank, to prevent rancidity due to oxidation and to lengthen its shelf life.

3b. PACKAGING MATERIAL (PM) STORAGE

QA Released PMs are stored properly designated storage area, wherein parameters such as humidity and
temperature are monitored until further processing.

3c. BAGGED MACRO RAW MATERIALS (RM) STORAGE (OPRP 1)

The QA Released Bagged RM’s are properly piled up in pallets inside the Warehouse for storage. Likewise,
storage parameters such as humidity and temperature during this step are monitored until further
processing.

3d. SILO STORAGE (BULK MACRO RM)

Once the bulk raw material has been brought to the silo storage, gravity will naturally control the flow at
which the grain reaches the bottom of the silo. At the bottom of the silo, there is an opening that connects
to an auger—a device used to safely transport grain from the silo storage to the feed mill.

3e. BAGGED MICRO RAW MATERIALS (RM) STORAGE

QA Released Micro RMs are properly stored in pallets inside the Warehouse, wherein storage parameters
such as humidity and temperature are monitored until further processing.

4a1. LOADING OF MACRO RAW MATERIAL (RM)

The feed mill has two main equipment, Ottevanger-Buhler and La Meccanica. Each equipment has Loading
pit located at staging area. Each loading pit has a dumping chute directly seated on a chain conveyor to
feed the raw materials to the bucket elevator. Each loading pit has a dust collection system, magnets and
grain cleaner.

4a2. BATCH WEIGHING OF MICRO RM’s

Micro ingredients (vitamins, minerals, premixes, and other micro-ingredients) are manually weighed and
batched per formulation. Batched RM’s are eventually tipped in Tipping Hopper. Toxin binder and feed
mitigant ingredients are manually weighed and recorded based on formula issued by Technical Service
Department. Some RMs (limestone, salt, meat and bone meal, etc.) are manually weighed according to
formulation. Every batch of RM’s are eventually tipped in Tipping Hopper.

4b1. AUTO DOSING

The Macro Materials from the bin are sequentially and automatically weighed by the use of load cell based
on formulation issued by the Technical Service Department and encoded in Dosing program. When all of
the materials of a batch are weighed on the Dosing Weigher and discharge the materials into the
conveyance towards the grinding bin.

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4b2. TIPPING 1

Manually weighed macro materials are poured into Tipping Hopper per batch and then transported thru the
Bucket Elevator towards the grinding bin.

4b3. TIPPING 2 (Ottevanger only)

Manually weighed macro materials are poured into Tipping Hopper per batch and then transported thru the
Bucket Elevator towards the grinding bin.

4b4. TIPPING 3

Manually weighed micro materials are poured into Tipping Hopper per batch including feed mitigant and
toxin binder

4c. GRINDING

The materials in the grinding bin will drop thru the slide gate into the Hammer Mill. The Hammer Mill grinds
the materials according to its particle size by the use of appropriate screens installed. Ground materials are
held into bin until the batch of materials are completely ground. When a batch of materials is completed,
they are then poured into the Batch Mixer.

4d1. LIQUID ADDITION (COCONUT OIL AND MOLD INHIBITOR)

During the execution of the dosing sequence, automatically weighed Coconut oil is injected into the Batch
Mixer. Automatically weighed mold inhibitor is also then sprayed into the Batch Mixer.

4d2. BATCH MIXING (OPRP 2 and 3)

The batched micro (including feed mitigant and toxin binder), macro, and liquid materials (coconut oil,
molasses, mold inhibitor) are homogeneously mixed by the use of a paddle - type for La Meccanica and
ribbon - type for Ottevanger-Buhler mixer. When the set mixing time is reached, the homogenized mash
feed will drop into Mash Bin.

4e. CONDITIONING (CCP 1)

The mash feed product will drop from the pre-pelleting bin to the common hopper directly seated on top of
the paddle-type feeder. The feeder will convey the mash product into the paddle-type conditioner chamber,
wherein steam is added. Retention temperature is monitored 45 – 60 minutes and the retention time is
monitored every change of product.

4f. PELLETING (OPRP 4)

The cooked mash is conveyed to the pelleting chamber where the mash is formed accordingly to pellet size
requirement. The pelleted products fall directly into the cooling chamber and eventually crumble if needed
in the process.

4g. COOLING

The pelleted products are cooled by the use of a counterflow cooler. The pelleted products are retained
(controlled by a level sensor) in the cooling chamber until they reach the ambient temperature and are then

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gradually discharged towards the crumbler or siever. Fines are collected by cyclone separator and then
dropped into the feeder part of the pelleting process.

4h. CRUMBLING

Products that require to be crumbled pass thru the crumbler. Crumbler is a set of two rollers that rotates in
opposite directions. The pelleted products will go between the rollers and be cracked into crumbles.
Crumble sizes are determined by adjusting the gaps between two rollers. Crumbled products are then
transported to the siever.

4i. SIEVING

Pelleted and crumbled products are fed into the siever. The siever is a machine with sets of screens that
separates the fines and under-sized pellets and crumbles from the conforming products. Fines are
transported to the hopper of the pelletizer for re-pelleting. All conforming pelleted and crumbled products
are transported to the designated bagging bin .

4j. BAGGING

Pelleted and crumbled products from the bin pass thru bagging hopper. These products are bagged into
appropriate sacks and sewed. Weight and the temperature of the bagged products are monitored. Bagged
pelleted and crumbled products are then transported to Finished Goods storage or FFS Packaging. Other
products with addition of grains will be transported to Compounding.

5. COMPOUNDING

Thunderbird Enertone pellets and Wingmaster pellets are further processed and mixed with different grains
by the use of one ton capacity ribbon - type mixer at the Compounding Area.

5a. GRAIN SIEVING

Grain ingredients passed thru Grain Sieving to remove dust particles, stalks, hulls and other foreign matters.
Grain siever is a vibratory equipment with perforated screens to remove contaminants and foreign materials.

5b. BATCH WEIGHING

Selected grain ingredients are manually weighed, according to the formulation, by batch and are then
transported into the hopper of the Batch mixer by use of a bucket elevator.

5c. LOADING

Batched grain ingredients and Thunderbird Enertone pellets are tipped in the loading pit directly seated on
the bucket elevator and transported to the batch mixer.

5d. BATCH MIXING

Batched grain ingredients and Thunderbird Enertone Pellets are homogeneously mixed by the use of a
ribbon-type mixer. When the set mixing time is reached, the Thunderbird Enertone final product is either
bagged into 25 kg laminated bags or stored into drums for further processing in Form-Fill-Seal (FFS) area.

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5e. BAGGING

Thunderbird Enertone final mix is bagged into 25 kg laminated bags. Weights of the bags are monitored
hourly by QA Inspector. Bagged Thunderbird Enertone Final are then transported to Finished Goods
warehouse.

Thunderbird Enertone final mix for use in FFS is stored into drums and transported to FFS area.

6. FFS PACKAGING

Compounded, pelleted and crumbled products are transferred to the Form–Fill– Seal (FFS) packaging area
for further processing.

6a. LOADING

Thunderbird, pelleted and crumbled products are dumped in the loading pit directly seated on the bucket
elevator and transported to FFS bin.

6b. PACKAGING

Compounded, pelleted and crumbled products from FFS bin directly transported to volumetric cup of FFS
machine for packing the products into 1 kg pouches.

6c. BAGGING/CODING

Products that pouched into 1 kg are bagged into a semi-transparent plastic bag. Each bag contains 24
pouches per 1 kg. Each bag has labeled stickers for both sides inner and outer of the bag. These bags are
then placed in pallets and transferred to Finished Goods warehouse.

7. KIDLAT

Multi Grain products are further processed and mixed at the Kidlat area.

7a. GRAIN CLEANER

Raw materials poured into the loading area are then conveyed to the Grain Cleaner. The raw materials
flow into the tremble from one side and then down through the screen towards the outlet for grains. The
foreign materials like stones and wood pieces are screened and transported towards an outlet for
waste. The cleaned RMs drop into a surge hopper and bagged into clean sacks.

7b. BATCH WEIGHING

Selected grain ingredients are manually weighed, according to the formulation, by batch and are then
transported into the hopper of the Batch mixer by use of a bucket elevator.

7c. LOADING

Batched grains ingredients are tipped in the loading pit directly seated on the bucket elevator and
transported to Batch mixer and polisher.

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7d. BATCH MIXING AND POLISHING

Batched grain ingredients are homogeneously mixed and polished by the use of a drum-type mixer and
polisher. When the set mixing time is reached, the Kidlat final product is bagged into 25 kg laminated bags.

7e. BAGGING

Kidlat final product is bagged into 25 kg laminated bags. Weights of the bags are monitored hourly by QA
Inspector. Bagged Kidlat final product are transported to Finished goods warehouse.

8. PREMIX

Micro-ingredient Premixes are part of the formulation used in the feed milling. Different micro ingredients
are mixed based on the formula issued by Technical Service Department.

8a. BATCH WEIGHING

Micro ingredients (vitamins, minerals, and others) are manually weighed and batched per formulation.
These are then manually tipped into the hopper of batch mixer.

8b. LOADING

Batched micro ingredients are tipped into the hopper directly seated on the batch mixer.

8c. BATCH MIXING

Batched micro ingredients are homogeneously mixed by the use of a ribbon - type mixer. When the set
mixing time is reached, the Micro Ingredient Premix product is bagged into 25 kg PE bags.

8d. BAGGING

Micro Ingredients Premixes are bagged into 25 kg PP bags. These are then transferred to Micro RM storage
area. Weights of the premixes are monitored hourly by QA Inspector.

9a1. LOADING OF MACRO RAW MATERIAL (RM)

The Extruder has main equipment, Buhler. It has Loading pit located at staging area. Each loading pit is
directly seated on a chain conveyor to feed the raw materials to the bucket elevator. It has a dust collection
system, magnets and grain cleaner.

9a2. BATCH WEIGHING OF MICRO RM’s

Micro ingredients (vitamins, minerals, premixes, and other micro-ingredients) are manually weighed and
batched per formulation. Batched RM’s are eventually tipped in Tipping Hopper. Some RMs (limestone,
salt, Poultry meal, etc.) are manually weighed according to formulation. Every batch of RM’s are eventually
tipped in Tipping Hopper.

9b1. Auto Dosing

The Macro Materials from the bin are sequentially and automatically weighed by the use of load cell based
on formulation issued by the Technical Service Department and encoded in Dosing program. When all of

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the materials of a batch are weighed on the Dosing Weigher and discharge the materials into the
conveyance towards the grinding bin.

9b2. TIPPING 1

Manually weighed macro materials are poured into Tipping Hopper per batch and then transported thru the
bucket elevator to conveyor towards the grinding bin.

9b3. TIPPING 2

Manually weighed macro and micro materials including toxin binder are poured into Tipping Hopper per
batch directly connected to batch mixer.

9b4. TIPPING 3

Manually weighed micro materials (Palatant powder) are poured into Tipping Hopper per batch directly
connected to fat coater.

9c. GRINDING

The materials in the grinding bin will drop thru the force feeder into the Hammer Mill. The Hammer Mill
grinds the materials according to its particle size by the use of appropriate screens installed. Ground
materials are held into bin until the batch of materials are completely ground. When a batch of materials is
completed, they are then poured into the fine grinding bin or vibratory siever.

9d. PULVERIZING

The materials in the fine grinding bin will drop thru the force feeder into the Pulverizer. The Pulverizer grinds
the materials into fine particle size. Fine ground materials are held into bin until the batch of materials are
completely ground. When a batch of materials is completed, they are then poured into the vibratory siever.

9e. VIBRATORY SIEVING

Ground and fine ground material are fed into the vibratory siever. The vibratory siever is a machine with
sets of screens that separates the oversize fines from the conforming fine materials. Oversize fines are
transported to the hopper of the hammer mill for re-grinding. All conforming fine materials are transported
to the batch mixer.

9f. BATCH MIXING

The batched micro, macro, and liquid materials (RBD coconut oil) are homogeneously mixed by the use of
a paddle-type mixer. When the set mixing time is reached, the homogenized product will drop into Rotary
Siever.

9g. LIQUID ADDITION (REFINED BLEACHED DEODORIZED COCONUT OIL)

During the execution of the dosing sequence, automatically weighed RBD Coco oil is injected into the Batch
Mixer.

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9h. ROTARY SIEVING

Homogenized product is fed into the rotary siever. The rotary siever is a machine with rotary drum that
separates the clumping product from the conforming product. Clumping product are transported to the
waste hopper. All conforming product are transported to the extruder bin.

9i. CONDITIONING

The mash product will drop from the extruder bin to the common hopper directly seated on top of the paddle-
type feeder. The feeder will convey the mash product into the paddle-type conditioner chamber, wherein
steam and steam condensate is added. Retention temperature is monitored 45 to 60 minutes and the
retention time is monitored every change of product.

9j. EXTRUDING (OPRP 5)

The cooked mash is conveyed to the extruder barrel where the mash is formed accordingly to kibble size
needed. The kibbled products are transported by pneumatic conveyor to dryer.

9k. DRYING (CCP 2)

The kibbled products undergo drying process. All kibbled products after dryer are transported by chain
conveyor to bucket elevator towards the fat coater. Retention temperature is monitored 45 to 60 minutes
and the retention time is monitored every change of product.

9l. VIBRATORY SIEVING

Kibbled products are fed into the vibratory siever. The vibratory siever is a machine with sets of screens
that separates the oversized kibbles from the conforming kibble size. Oversized kibbles are transported to
the waste hopper. All conforming kibbles are transported to the fat coater.

9m. FAT COATING

Kibbled products are passed thru the Fat coater. The Fat coater is a machine with sets of nozzles that spray
the products with oil evenly using paddle type mixer after the kibble are dried and sieved. All conforming
coated products are transported to the cooler.

9n. COOLING

The kibbled products are cooled by the use of a counterflow cooler. The kibbled products are retained
(controlled by a level sensor) in the cooling chamber until they reach the ambient temperature and are then
gradually discharged towards the siever. Fines are collected by cyclone separator.

9o. VIBRATORY SIEVING

Kibbled products are fed into the siever. The siever is a machine with sets of screens that separates the
fines and undersized kibbled from the conforming products. Fines are separated to waste hopper. All
conforming kibbled products are transported to the designated bagging bin.

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9p. BAGGING

Kibbled products are packed into laminated bags, heat sealed and sewed. Weight and the temperature of
the bagged products are monitored. Bagged kibbled products are then transported to Finished Goods
warehouse.

10. FG STORAGE

Finished goods are stored in the Finished Goods Warehouse in pallets. Finished goods are served using
FIFO (First In First Out) Inventory System.

11. FG WITHDRAWAL / LOADING

FG WITHDRAWAL

Serving of finished goods begins with the receiving of customer order coordinated with Customer
Relations Management Group (CRMG). Received customer orders are being approved by Credit
Department. Finished Goods section of the Warehouse Department issues pick slip to approved
customer orders.

LOADING

Finished Goods section of the Warehouse Department calls the attention of customer truck driver
and/or helpers. Customers scheduled to be loaded are requested to weigh in their trucks and proceed
to loading bay.

Truck driver or helper will submit to warehouse office the final counting of loading checker together with
the counting of forklift operator, guard checker and weigh out receipt. Finished Goods section of the
Warehouse Department will issue corresponding sales invoice and delivery receipt after counter-
checking has been made by warehouse office clerk.

History of the Document

Revision Number Date Approved Description of Changes

Prepared by Reviewed by Approved by Issued by

OD Rosales FS Ferrer / MO Cruz MA Sison MR Morales

Process Engineer Plant Head / Deputy PSQMR PSQMR Document Controller

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