Rice Haccp [PDF]

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MyHACCP Study: rice and paddy processing Business name: ama



This document was created using the MyHACCP web tool. http://myhaccp.food.gov.uk



Date generated: 05/10/2019



Management commitment The following evidence shows the support of senior management to food safety management based on HACCP: A Food Safety Policy has been drawn up and signed by management. Training takes place for HACCP studies.



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Terms of reference This Modular HACCP plan covers: processed rice packed in plastic bags of 3 and 5 kgs It will start at incoming inspection through to dispatch.



The HACCP plan will cover final product safety and will look at the following hazards:



Physical Metal Wood splinters Stones Insects Hair Feathers Finger nails Pests



Chemical Agricultural residues: Pesticides Heavy metals Environmental contaminants



The company has in place a number of effective prerequisite programmes, including: Supplier approval Incoming material specifications Finished product specification Training (incl. training needs analysis, job descriptions) Contract services (i.e. waste/laundry) Pest Control Calibration Standard Operating Procedures (SOPs) Product recall Document control 2 / 18



Audit schedule (incl. HACCP/internal audits) Customer complaints Tracking non-conformances Microbiological control Preventative maintenance Traceability Equipment suitability, cleaning and maintenance Measures to prevent cross-contamination Cleaning and sanitising Personnel hygiene and employee facilities Warehousing Contamination control



The location of the above documents is: in the plant / on -site



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The HACCP team Role



Name



Training



Qualifications



Experience



HACCP lead



ABC (Internal)



done



yes



10years



quality check



XYZ (Internal)



yes



done



5years



We confirm that the team have sufficient skills (scientific/technical knowledge and HACCP expertise) to ensure that the HACCP study will be effective.



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Product description and intended use Ingredients rice and paddy



Physical properties solid pH moisture



Processing less moisture



Packaging plastic bags



Storage in storage bins by trucks



Shelf life of product 3 to 4 years



Storing, handling and preparation advice keep at dry and cold condition



Intended Use Name of the product: rice The product is suitable for consumption by the general public. The product is suitable for the young. The product is suitable for the elderly. The product is suitable for pregnant ladies. The product is suitable for the immunosuppressed / immunocompromised. The product is suitable for people with allergies or intolerances. 5 / 18



We have considered the likely abuse / unintended use of the product by the consumer in the following ways: they will not



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Process flow and confirmation We have completed a flow diagram covering all steps in the manufacturing process of this product. See Appendix A for the flow diagram.



On-site confirmation of flow diagram abc has confirmed that our flow diagram is correct. Every process step is identified in our flow diagram. The flow diagram is an accurate representation of the process from start to finish. The flow diagram is correct for all shifts (e.g. days, nights and weekend). The flow diagram is correct during all seasonal variations. The HACCP lead has signed off and dated the flow diagram as being correct.



The following members of our organisation are responsible for making changes to the flow diagram and storing out of date versions: FSTL



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Identify and list potential hazards Step No.



Step Name



Biological



Chemical



Physical



Allergens



1



paddy receiving



Chances of microbial contamination due to improper handling of raw material by food handler, microbes contamination and Illness of the employee.



Pesticide residue, Heavy Metals, Banned chemical usage, Undeclared allergens etc.



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



e-coli bacteria



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Severity scores 1. paddy receiving Hazard



Hazard Description



Severity



Likelihood



Significance



Chances of microbial contamination due to improper handling of raw material by food handler, microbes contamination and Illness of the employee.



[1] Effective control of supplier & processing. [2] Effective PRP in place ( Due to source of harvesting, packing & transportation condition )



2



2



4



Pesticide residue, Heavy Metals, Banned chemical usage, Undeclared allergens etc.



[1] Effective control of supplier & processing. [2] Heavy Metals test results. (Due to improper pesticide treatment, usage of banned pesticide & heavy metal contamination in the agriculture land itself). [3] Insects and rodents pest are natural reservoir of many bacterial pathogens. [4] From the farmer source and soil source. [5] Undeclared allergen also hamper the product.



3



1



3



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



Effective control of supplier & processing. Effective PRP in place ( Due to source of material packing & transportation condition) Likely to occur.



3



2



6



e-coli bacteria



bacteria contamination



3



1



3



The threshold, above which we consider the hazard to be 'significant' is: 5



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Control Measures Step No.



Step Name.



Hazard



Hazard Description



Control Measures



1



paddy receiving



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



Effective control of supplier & processing.



[1] Approval, evaluation & reevaluation of suppliers. [2] RM specification give to the supplier & purchase of material after approval of the sample [3] Vehicle Cleanliness check [4] Good handling & Good hygiene practices are follow [5] Supplier visit - once / year for site visit. [6] Inspection at receiving according to Quality Plan



Effective PRP in place ( Due to source of material packing & transportation condition) Likely to occur.



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CCPs for significant hazards For this study, we are using the Codex decision tree. Step No.



Hazard



Control Measures



Decision Tree



CCP?



1



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



[1] Approval, evaluation & re- evaluation of suppliers. [2] RM specification give to the supplier & purchase of material after approval of the sample [3] Vehicle Cleanliness check [4] Good handling & Good hygiene practices are follow [5] Supplier visit - once / year for site visit. [6] Inspection at receiving according to Quality Plan



Q1: Yes Q1a: N/A Q2: No Q3: Yes Q4: No



Yes



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Critical limits for the CCPs The following critical limits have been established for the CCPs. Step No.



Step Name.



Hazard



Critical limit



How was the critical limit determined?



Will the critical limit control the specific hazard?



Can the critical limit be measured or observed in real time?



1



paddy receiving



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



0% metal particles



using heavy magnets



Yes



Yes



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The HACCP Plan Process step



Step no.



Hazard



Control measure



Critical limit



Monitoring procedures



Corrective action



paddy receiving



1



Chance of Foreign material such as Wood, Metal, Dust, immature paddy, Inferior quality material, etc.



[1] Approval, evaluation & re- evaluation of suppliers. [2] RM specification give to the supplier & purchase of material after approval of the sample [3] Vehicle Cleanliness check [4] Good handling & Good hygiene practices are follow [5] Supplier visit - once / year for site visit. [6] Inspection at receiving according to Quality Plan



0% metal particles



check the calibration of magnets at regular intervals



Corrective action to be taken: change the magnets



Monitoring activity frequency: twice every day



Personnel who have the authority to take the stated corrective action: FSTL/MD



How the monitoring activities are carried out: manually The following people are responsible for monitoring actions at this CCP: FSTL / minions The deputy is: QC The results of monitoring are recorded: log register



all things stops Actions for product produced when the CPP was out of control will be recorded in: log register 2 All personnel are trained and competent for performing the activities stated. Records of competency are maintained.



Monitoring records will be checked and signed off by FSTL/ceo at the frequency of: daily



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Verification Validation study check with master magnet FSTL/MD/CEO is responsible for ensuring the contents of the HACCP plan are validated and will also formally sign off the HACCP plan.



The following verification activities are undertaken: Internal audits of Critical Control Points Prerequisites Records of monitoring Corrective actions



Finished product Microbiological testing



Interim product Microbiological testing



Other Addressing the findings of customer and third party audits Trending and analysing customer complaints



Reviewing Deviations Corrective actions



Other verification activities no other verification



All verification records are maintained



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The HACCP system is formally reviewed twice annually. CEO/MD is responsible for carrying out a formal annual review.



The following triggers will initiate a review in the organisation: Technological advances in production New controls that become available Change in raw material/ingredients/product formulation/packaging Modification to process equipment (e.g. new equipment, modification of existing equipment) Failures in the system, e.g. corrective actions or the need for product recall/withdrawal Emergence of foodborne pathogens with public health significance Changes in legislation Environmental changes/issues (i.e. local changes external to the food operation; climate changes) Other mechanisms that will automatically trigger a review: none All records from reviews are documented, brought to the attention of senior management and used to keep the HACCP plan up-to-date.



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Documentation and record keeping Documentation relating to this HACCP study that the business retains: Scope of the study Reference to prerequisite programmes HACCP team members with details of their role, experience, training and qualifications Product description Intended use of the product Flow diagram, and the confirmation that it is correct Relevant hazards (as determined from the hazard analysis) and control measures Details of all CCP’s that have been determined The critical limits at the CCP’s, with targets and tolerances where relevant The corrective action plan for each CCP Reference to relevant procedures/work instructions and record forms



Other supporting information that is retained none



Documentation control issue number The maximum length of time we retain this information for is 3 years / shelf life All records are accessible, accurate and up to date.



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Appendix A - Flow Diagram The flow diagram begins on the next page.



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