HACCP PLAN

Contents
HACCP TEAM AND THE RESPONSIBILITIES..................................................................................................................................................................3
Product Description...................................................................................................................................................................................................6
Product characteristics:.................................................................................................................................................................................................... 6
Microbiological characteristics:........................................................................................................................................................................................ 6
Sensory characteristics:.................................................................................................................................................................................................... 6
Intended use.................................................................................................................................................................................................................... 7
Process Flow diagram of the product.........................................................................................................................................................................8
HAZZARD ANALYSIS..................................................................................................................................................................................................9
CCP................................................................................................................................................................................................................................. 14
OPRP............................................................................................................................................................................................................................... 14
HACCP TEAM AND THE RESPONSIBILITIES

Name and the designation Qualifications Responsibilities and Authorities

1.CEO - 15+ years industry Responsible on overall.

experience Management of the company including decisions.
-B.Sc. Business Responsible on providing resources with commitment. Review skills of employees.
Management, MBA

2.Head of - ISO 22000 & BRC -Ensure that the process needed for the FSMS are established, implemented & maintained.
Quality/Production trained -Liaise with external parties on matters related to FSMS.
-40 years industry - Review of Food safety Manual & Procedures.
experience -Practical understanding on coconut and dehydrated product processing activities.
-M.Sc. Food Science & -Conduct management review.
Nutrition - Review of Food safety Manual & Procedures.
- ISO 14001 lead
auditor trained.
3. Maintenance Manager - ISO 22000 & BRC -Responsible for machine cleaning
trained -Responsible for external service schedules
18 years industry -Responsible for machinery repair and periodical services
experience as -Responsible for Health and Safety
Maintenance
Executive.

4. Manager – QA & RD - FSSC 22000 Lead -Maintain the relationship between relevant stakeholders with related to food safety and
Auditor quality
4 Year experience in food -Implementation of approved policy matters
industry /decisions.
-Handling customer complaint and Obtaining customer feedbacks and forward such
BSc.(sp) Food science &
information to relevant Departmental.
Technology -Develop and implement best food hygiene practices.
-Conduct Internal food safety audit and maintain records
-Ensure the promotion of awareness of customer requirements throughout the company
5.Asssistant manager-QA & -ISO 22000 and BRC -Implementation of approved policy matters
PD/FSTL trained /decisions.
3 year experience -Handling customer complaint and Obtaining customer feedbacks and forward such
in food industry information to relevant Departmental.
Qualifications BSc. -Develop and implement best food hygiene practices.
(sp) Agric. Business -Conduct Internal food safety audit and maintain records
Management -Ensure the promotion of awareness of customer requirements throughout the company

6. Production Manager -ISO 22000/BRC -Responsible for all manufacturing activities of the Oil Extraction operation with the guidance
trained of the reporting manager.
3 and half year -Production planning and daily production monitoring
experience in food -Implement and maintaining production documents
industry -Work with Manager - Production for managing and monitoring the employees and their
performance, assigned to the department.
Bsc. Chemistry
7. Quality Assurance -ISO 22000/BRC -Responsible on food safety management system.
Executive trained -Responsible for day today documentation work and QA Activities
5year experience in -Testing of samples for chemical and microbiological parameters.
food industry - Monitor CCP’s timely. Maintain better cleaning everywhere and personal hygiene in all
Bsc (Hons) in Agriculture employees.

8. Manager Procurement -ISO 22000/BRC -Responsible for food safety purchasing process.
Control and Financing trained -Conducting internal audit for food safety
-7 years experienced in -Maintain the stores and stock sheets.
food industries. -Responsible for supplier approval and evaluation process
-B.Sc Applied
Accounting Degree/
CBA/Associate
Member of ISMM
-FSSC 22000 LA

09.Accountant Executive -ISO 22000/BRC -Responsible in financial handling of company

trained -Responsible for food grade purchasing.
-Responsible for supplier approval and evaluation process
-10 years experienced in
food industries.

-Chartered Passed
Finalist
Product Description
Product Butter Cake
Wheat flour, sugar, eggs, salt, vegetable fat, glycerol, starch, wheat starch, skim milk powder,
Product composition
raising agents (E 500), preservative (E 202), and flavor.

Product characteristics:
Moisture 18-22 % w/w
Water activity (aw) 0.76-0.81
Acid Value of extracted fat, (as oleic acid),
1.0
percent by mass, Max.

Microbiological characteristics:
Total viable count, cfu/g, Max. 20000
Enterobacteriaceae spp. < 102 UFC/g
Staphylococcus aureus < 102 UFC/g
Salmonella spp. Absent
Listeria monocytogenes Absent
Coliform Absent
Mold cfu/g, maximun 50

Sensory characteristics:
Physical condition Solid
Color Characteristics
Flavor Typical
Texture Typical
Product's name, composition, allergen information, origin, manufactures date, expiry date,
Labeling requirements
destination, net weight, storage temperature, and destination.
Primary packages should be packaged further in a secondary packing procedure (gift boxes).
Storage and transport
Secondary boxed must packed in tertiary packaging (cartons). Final storage and transportation
Conditions should make at ambient temperature.
Shelf life 4 months
Intended use
Direct consumption. The product mentioned is for the general population, except for gluten sensitive
groups.
Process Flow diagram of the product

Receiving of Raw Materials Unloading area

Storage of Raw materials

Raw materials storage

Eggs breaking and weighing of raw materials Depositing area

Mixing Ingredients

Dough Dosing
Oven area

Bake in oven

Cooling

Primary Packing area

Primary Packaging

Secondary Packing
Secondary Packing area

Finished goods storage

Warehouse

Distribution
HAZARD ANALYSIS
HACCP
Don’s Cake Revision No 01 dated 06/06/2024 Date of Issue 01 dated 05/06/2023 Page 01

HAZARD ANALYSIS
Hazard Identification & risk assessment Categorization of Control Measures
Probab Risk (P x S)
Severity Control/ Preventive
Process ility
H – 60 -100 Reason for
step Hazard Cause/ Justification (L- 3) Measures Q1 Q2 Q3 Q4 Q5
(L- 3) Decision
(AV-5) AV – 30- 59
(AV-6)
(H-10)
(H-10) L – below 30
Dry storage at room temperature
(25-30 C)
Rh = 90-92% Time less than 1 Contamination
Biological: Microbial
month in
contamination L H L Y Y N Y Y
Supplier evaluation, , transportation
(pathogenic).
HACCP certificate, vehicle
personal and transport
01.Receiving
of raw and hygiene status, lab test
packaging
materials Contamination
Supplier evaluation, in
Acidity,
HACCP certificate, transportation
melamine, heavy
Chemical: L H L personal and transport Y Y N Y Y vehicle,
metals, & residual
hygiene status, lab test intentional
chemical etc. Packaging.
(QA) added
chemicals.

Foreign
Improper
objects, such as
Physical: AV L L Visual inspection Y Y N Y Y storage at
hair, insects, broken
transporting.
plastics etc.
Storage of Biological: Microbial, pests and L H L FIFO, maintaining Y Y N Y Y Irregular
raw and insects. suitable storage and inspection and
packaging transport temperature, improper
materials pest controlling plan, hygiene
maintain personal and
environmental hygiene
during storage and
 transport.

Chemical: Storage
Production of H2S Maintaining suitable
AV L L temperature
(eggs) storage condition, FIFO N

Keep storage Transport and

environment safe, keep storage
Foreign
Physical: H L L containers closed. Y Y N N PRP temperature,
objects, insects.
Separate areas for raw pest
and packaging materials. control, hygiene

Improper
Maintain personal handling and
Biological: Microbial contamination hygiene, wear mask, personal
L L L Y Y N N
apron, gloves, head cover hygiene
and beard cover ,

Taking RM
and PM Cleaning chemicals of
Chemical: Not properly
from equipment’s’ L L L Properly clean the equipment’s Y Y N N clean the
storage to equipment’s
production
Improper
Maintain personal handling and
Foreign hygiene, wear mask, personal
Physical: H L L Y Y N Y Y
objects. apron, gloves, head cover hygiene
and beard cover ,

Strict personal hygiene,

Improper
regular hand swab tests
Pathogenic handling and
Biological:. L H L by the QA, proper Y Y N Y Y
microorganism personal
hygiene, food safety, and
hygiene
behavioral training,

Follow the recipe and

Batch Excess Incorrect
recheck, timely
preparation Chemical: additives, L L L hygiene
calibration of measuring
(weighing detergents etc.. and cleaning
and instruments
mixing)
Provision of filter in egg
broker machine, visual Improper
Foreign
inspection, maintaining handling and
Physical: objects, broken egg AV L AV Y Y N Y Y
personal hygiene, wear personal
shells.
mask, apron, gloves, head hygiene
cover and beard cover

Mixing Biological:. Pathogenic L H L Maintain strict personal Y Y N Y Y Improper

microorganism hygiene, wear mask, handling and
apron, gloves, head cover personal
 and beard cover, keep the
equipment properly hygiene
sanitized

Incorrect
Maintain proper hygiene
Chemical: Detergents residue L L L Y Y N Y Y hygiene
and cleaning practice
and cleaning

Checking the status of Maintenance of

Broken mixing machine, mixing
piece of mixing maintain personal machine,
Physical: H L L Y Y N Y Y
machine hygiene, wear mask, improper
Foreign objects apron, gloves, head cover personal
and beard cover hygiene

Improper
Biological: Maintain proper hygiene handling and
Microbial contamination L L L Y Y N N
and cleaning practice personal
hygiene

Chemical: Incorrect
Maintain proper hygiene
Detergents residue L L L Y Y N N hygiene
and cleaning practice
and cleaning
Dosing
Maintenance of
the
Broken Dosing machine
Checking the status of
Physical: piece of dosing L L L Y Y N Y Y
dosing machine
nozzle improperly,
personal
hygiene

Maintenance of
the
Biological: Microbial Maintenance of baking oven ,
L H L Y Y N Y N
contamination temperature & time improperly,
personal
hygiene

Maintenance of
Frequent lab test for MC
Baking Moisture the
and aw from each batch,
Chemical: content and water H L L oven ,
maintenance of baking
activity improperly,
temperature & time personal
hygiene
Maintenance of
Physical: the
Metal and nonmetal Checking the status of oven ,
L L L Y Y N N
particles dosing machine improperly,
personal
hygiene
 Holding Time less than 20min,
Maintenance of
Temperature20-25C
the
Biological: Compliance with good personal cooling
Microbial contamination L L L Y Y N Y Y machine ,
hygiene practices. Perform the task
improperly,
quickly, hygienically and without
personal
interruptions. hygiene

Maintenance of
Cooling
the
Moisture Check for cooling
cooling
Chemical: content and water AV L L conveyor speed and
Y Y N Y Y machine ,
activity cooling temperature improperly,
personal
hygiene
Maintenance of
the
Physical: cooling
Metal and nonmetal
L L L Properly maintain the machine Y Y N Y Y machine ,
particles
improperly,
personal
hygiene
Biological;
Absent

Chemical::
Absent

Metal Maintenance of
detection the
cooling
machine ,
Metal Frequent checking of the improperly, Not
Physical: H H H Y Y Y N N
parts machine status frequently
checking of the
machine status

CCP

Improper
Regular hand and surface
personal
swab test, ATP check
Biological: Microorganisms hygiene,
Packaging before packing, strict
AV H AV S Y N Y N contamination
maintaining of personal
in
hygiene, QA check
packing
for leak package
materials

Chemical:. Detergents residue L L L Maintain proper hygiene Y Y N Y Y Improper

 and cleaning practice cleaning

Foreign Improper
parts from Proper cleaning of cleaning of
packaging machine packaging machine, packaging
Physical: AV L L Y Y N Y Y
surface, damaged check for nitrogen gas machine,
pack, leakage in level.
packing

Filling in
box & date
No hazard
coding

Biological: Temperature 25-30C for a Improper

maximum 5-7 days handling and
Microbial contamination L L L N N
personal
hygiene
Finished
Chemical:
Goods
Hazardous chemicals and Maintain proper hygiene Improper
storage L L L N N
allergens. and cleaning practice cleaning

Tertiary Put glue trap in proper No pest traps

Physical: package damage by L L L places, conduct timely N N and
rodents pest control action pest control
CCP

Critical
Process Control CCP/ Monitoring (Codex 9) Corrective Verification
Limit Records
step/ Hazard Measure CP/ (Codex 8) Action Who & When
(Codex 12)
Input (Codex 6) (Codex 7) What Where How When Who (Codex 10) (Codex 11)
Metal Physical: Detection CCP Absence of Sensor of Primary Physical Every 1hr Maintenance Rejection of In house QAE ,Produc
Detection Metallic of metallic metallic the metal Packing Inspection interval dept., QAE & the whole lot checking by tion team
component component component detector, area and check during the production of non- metal pieces,
by metal PLC, for alarm production dept. conformed maintenance
detector alarm (by time products records,
passing a calibration of
metal metal detector,
under the and auditing
metal
detector

OPRP
Critical Verification
Process Control CCP/ Monitoring (Codex 9) Corrective Records
Limit Who &
step/ Hazard Measure CP/ (Codex 8) Action (Codex
When
Input (Codex 6) (Codex 7) What Where How When Who (Codex 10) 12)
(Codex 11)
Baking Biological: Maintenance Baking Oven Oven Physical Every 1hr QAE, Reset the Physical QAE ,Produ
Microbial of baking temperature temperature area inspection interval Production temperature observation ction team
contamination temperature between during the and time, , calibration
& time as 150-
team reject or
production
per SOP 250°C for time reuse the
5-50 product
minutes