HACCP Generic Model for Fresh Non-Filled Alimentary Paste
HACCP Generic Model: Fresh Non-Filled Alimentary Paste - Forms

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Example of Completed Form 1: Product Description Process for Fresh Non-Filled Alimentary Paste

Note: The manufacturer should list all products on Form 1, including all sizes of packages manufactured for each product, or the manufacturer may reference a computer file where a complete list of products including various package sizes can be accessed.

1. Product name

Fresh non-filled alimentary paste

2. Important product characteristics (aw, pH, preservatives, etc.)

Nil

3. How the product will be used

Cook and serve

4. Packaging

  • plastic bags
  • foil trays with cardboard lids
  • plastic clam shells
  • hard plastic trays
  • plastic film
  • corrugated cardboard boxes

5. Shelf life

"X" Days at "Y" Degrees

6. Where it will be sold

  • Hospital
  • Restaurant
  • Institutions
  • Retail

7. Labelling instructions

  • Keep refrigerated
  • Cooking instructions
  • Lot Code
  • Best Before Date
  • "May contain X" (precautionary labelling where X refers to the allergens that may be present in the product)

8. Special distribution control

Refrigerated distribution - maintain at C

Example of Completed Form 2: List of Product Ingredients and Incoming Material

Legend: Explanation of Codes

  • (B) = Biological hazard
  • (C) = Chemical hazard
  • (P) = Physical hazard

Flour

  • durum semolina (BCP)
  • wheat flour (BCP)
  • soy flour (BCP)
  • rice Flour (BCP)

Egg Products

  • liquid whole egg (pasteurized) (BCP)

Water

  • municipal water/well water (BCP)

Spices

  • spices (BCP)

Other Ingredients

  • tomato powder (BCP)
  • spinach powder (BCP)
  • garlic powder (BCP)

Packaging Material

  • plastic clam shells (BCP)
  • hard plastic trays (BCP)
  • plastic bags (BCP)
  • corrugated cardboard boxes (BCP)
  • foil trays (BCP)
  • cardboard lids (BCP)
  • plastic film (BCP)

Example of Completed Form 3: Process Flow Diagram

This diagram is a flow chart showing the process for producing fresh non-filled alimentary paste. Description follows.
Description of the Process Flow Diagram

This diagram is a flow chart showing the process for producing fresh non-filled alimentary paste.

The diagram lists the necessary steps from 1 - 14 to be taken in the fresh non-filled alimentary paste production process.

Identified in pink ovals are the Critical Control Points (CCPs). These are next to boxes 7, Ingredient weighing/measuring/mixing; 11, Weighing/packaging/labelling/coding; and 12, Metal detection.

Identified in an orange oval is water. This inputs to step 7, Ingredient weighing/ measuring/mixing. Also identified in an orange oval is rework. This receives inputs from steps 8, Sheeter/former/extruder; 9, Cooling/drying; and 10, Cutting; and leads to steps 7, Ingredient weighing/measuring/mixing; and 8, Sheeter/former/extruder.

Identified in a beige oval is returned product which leads to disposal, identified in a grey oval.

Potential for Biological (B), Chemical (C) and/or Physical (P) hazards is indicated in parentheses next to each process step.

Step 1. Receiving (BCP). Leading to steps 2, Flour storage; 3, Dry storage; 4, Liquid whole egg (pasteurized) storage; and 5, Packaging material storage.

Step 2. Flour storage (BCP). Leading to step 6, Sifting/screening.

Step 3. Dry storage (spices and other ingredients). (BCP). Leading to steps 6, Sifting/screening; and 7, Ingredient weighing/measuring/mixing.

Step 4. Liquid whole egg (pasteurized) storage (BCP). Leading to step 7, Ingredient weighing/measuring/mixing.

Step 5. Packaging material storage (BCP). Leading to step 11, Weighing/packaging/labelling/coding.

Step 6. Sifting/screening (BCP). Leading to step 7, Ingredient weighing/measuring/mixing.

Step 7. Ingredient weighing/measuring/mixing (BCP). CCP-1C. Leading to step 8, Sheeter/former/extruder.

Step 8. Sheeter/former/extruder (BCP). Leading to/receiving input from rework. Leading to steps 9, Cooling/drying; and 10, Cutting.

Step 9. Cooling/drying (BCP). Receiving input from step 10. Leading to rework and steps 10, Cutting; and 11, Weighing/packaging/labelling/coding.

Step 10. Cutting (BCP). Leading to rework.

Step 11. Weighing/packaging/labelling/coding (BCP). CCP-2C. Leading to step 12, Metal detection.

Step 12. Metal detection (BCP). CCP-3P. Leading to step 13, Storage.

Step 13. Storage (BCP). Leading to step 14, Shipping/distribution.

Step 14. Shipping/distribution (BCP).

Example of Completed Form 4: Plant Schematic

Construct the plant schematic diagram on Form 4.

Note: This form is to be specific for each establishment.

Indicate the flows of raw and finished products as well as employee traffic and, where a possible hazard exists, the movement of waste or garbage.

Include the flows of all ingredients and packaging materials from the moment they are received through storage, preparation, processing, packaging, finished product holding and shipping.

Indicate employee traffic patterns throughout the establishment from the time the employees enter the building, Include movement into change rooms, washrooms, lunchrooms, offices and maintenance, as well as the employee's movement through food production areas of the facility. Where applicable, it is important to clearly identify the traffic flow of employees handling raw products and those employees handling finished products.

This diagram should be your primary tool for identifying potential areas of cross-contamination (e.g. locations where allergen ingredients, food additives, waste or raw ingredients could come into unplanned contact or where employees could cross contaminate product).

(See Canadian Food Inspection Agency FSEP Manual – Section 3.2.4)

Note: The points of cross-contamination should be marked on the plant schematic and a full description of each of the identified hazards should be recorded on Form 5, 6 and/or 7, Form 8 and where appropriate, Form 10 (examples of possible hazards that could be identified on Form 4 are provided on Form 5 and Form 6).

Example of Completed Form 5: Biological Hazards Identification

Pathogenic microorganisms when used in this generic model may include: Salmonella spp., Listeria monocytogenes, pathogenic strains of Escherichia coli, Clostridium botulinum, Clostridium perfringens, Staphylococcus aureus, Bacillus cereus, and viruses (Hepatitis A virus and Norovirus).

Product name: Fresh Non-Filled Alimentary Paste
List all biological hazards related to ingredients, incoming material, processing, product flow, etc.
Identified biological hazards (Bacteria, parasites, viruses, etc.) Controlled at
Flour – Presence of Bacillus cereus in flour at levels significant to food safety. Not likely to occur in excess of the acceptable food safety levels.
Flour – Presence of Salmonella spp. in flour. Transportation, Receiving and Storage B2.1.3 (of the FSEP Manual)
- Section 1.4.1 (of the guidance document)
Liquid whole egg (pasteurized) – Growth of sporulating pathogenic bacteria due to elevated storage temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse) at the supplier level and/or during transportation. Transportation, Receiving and Storage B1.1.1 and B2.1.3
- Section 1.4.1
Liquid whole egg (pasteurized) – Presence of pathogenic bacteria (e.g., Salmonella spp., Listeria monocytogenes, Staphylococcus aureus) due to ineffective pasteurization and/or improper handling procedures at the supplier level. Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Water/Well Water – Not meeting the Guidelines for Canadian Drinking Water Quality published by Health Canada as well as any provincial or municipal requirements. Premises A4.1.1 and A4.1.2
- Sections 3.4.1 and 7.4.1
Spices – Presence of pathogenic microorganisms due to inadequate antimicrobial treatment. Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Spices/ other ingredients – Presence of pathogenic microorganisms in spices and/or other ingredients due to improper handling at the supplier level. Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Packaging Material – Presence of pathogenic microorgansims on packaging material due to damage or soiling as a result of mishandling at the supplier level. Transportation, Receiving and Storage B2.1.3
- Section 1.4.2
Packaging Material – Presence of pathogenic microorganisms due to contamination with faecal material from pests (rodents, birds and insects). Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging material – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients and/or packaging material with pathogenic microorganisms during transportation due to unclean/damaged packaging and/or unclean/damaged vehicles used for transportation from supplier(s) to manufacturer. Transportation, Receiving and Storage B1.1.1 and B2.1.3
- Section 1.4.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to improper employee hygiene and handling. Personnel D1.1.1, D2.1.1 and D2.2.3
- Sections 5.1.1, 5.2.1 and 5.2.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to contamination from overhead structures (e.g., leaking pipes). Premises A2.1.2 and A2.3.1
- Sanitation and Pest Control E1.1.2
- Equipment C1.1.1 and C1.2.1
- Sections 2.1.1, 2.1.3, 3.2.1, 3.2.3 and 4.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Growth of pathogenic microorganisms in liquid whole egg (pasteurized), rework, dough and/or finished product due to exposure to elevated room temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse). Transportation, Receiving and Storage B2.1.1, B2.1.2 and B2.2.2
- Equipment C1.2.1
- Sections 1.6.1, 2.1.3, 2.1.4, 6.2.1 and 6.2.3
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to contact with pests (flies, rodents, birds). Sanitation and Pest control E2.1.1
- Section 4.2.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms as a result of exposed product due to improper storage procedures. Transportation, Receiving and Storage B2.1.2 and B2.2.2
- Sections 1.6.1, 6.2.1 and 6.2.3
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms as a result of exposed product due to improper employee hygiene and handling. Personnel D1.1.1 and D2.1.1
- Sections 5.1.1, 5.2.1and 5.2.2
1,2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms due to contact with unclean tools, utensils & equipment as a result of improper sanitation procedures. Sanitation and Pest Control E1.1.1
- Section 4.1.1
1, 6, 7, 8, 9, 10, 11, 12 – Contamination of dough, rework, finished product and/or packaging material with pathogenic microorganisms due to inadequate separation of production and packaging areas from facilities for equipment cleaning and sanitizing. Premise A2.2.1
- Section 3.3.2
1 Receiving – Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient. Transportation, Receiving and Storage B1.2.1 and B2.1.3
- Personnel D1.2.1
- Sections 1.1.4, 1.4.1, 1.4.2, 5.2.2 and 6.1.2
1 Receiving – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging material with pathogenic microorganisms from contaminated raw products (non-ready-to-eat) carried on the same truck. Transportation, Receiving and Storage B1.1.2 and B2.1.3
- Personnel D1.2.1
- Sections 1.1.4, 1.4.1, 1.4.2, 5.2.2 and 6.1.2
1 Receiving – Contamination of dough, rework and/or finished product due to failure to properly identify, isolate and/or dispose of returned product when received. Premises A2.1.1
- Transportation, Receiving and Storage B2.1.2
- Personnel D1.2.1
- Sections 1.8.1, 3.2.1, 5.2.2 and 6.2.3
2, 3, 4, 5, 6, 7, 8, 9, 10, 11 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms due to contaminated room air. Premises A2.1.1 and A2.3.1
- Sections 3.2.1 and 3.2.3
4 Liquid Whole Egg (Pasteurized) Storage – Growth of pathogenic microorganisms in liquid whole egg (pasteurized) in storage due to failure to rotate incoming product (first in, first out). Transportation, Receiving and Storage B2.1.2
- Sections 1.5.1 and 6.2.1
4 Liquid Whole Egg (Pasteurized) Storage – Growth of pathogenic microorganisms in liquid whole egg (pasteurized) due to elevated storage temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse). Transportation, Receiving and Storage B2.1.1 and B2.1.2
- Equipment C1.2.1
- Sections 1.5.1, 2.1.3, 2.1.4 and 6.2.1
6, 7, 8, 9, 10, 11 – Contamination of subsequent lots/batches of dough and/or finished product with pathogenic microorganisms due to failure to adequately clean product residue from machinery between lots/batches/products. Sanitation and Pest Control E1.1.1
- Personnel D1.2.1
- Section 4.1.1 and 5.2.2
6, 7, 8, 9, 10, 11 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished products and/or packaging materials due to presence of pathogenic microorganisms on damaged and/or deteriorating surfaces of equipment, conveyors, tools and/or utensils (i.e., presence of pathogenic microorganisms in cracks and crevices). Equipment C1.1.1 and C1.2.1
- Sanitation and Pest Control E1.1.1
- Sections 2.1.1, 2.1.3 and 4.1.1
7, 8, 9, 10, 11, 12 – Contamination of dough, rework and/or finished product with pathogenic microorganisms present at specific points in the process where improper line design, improper equipment design and/or incomplete cleaning allow product and/or moisture to accumulate (e.g., improper welds, dead end pipes, sharp angles). Equipment C1.1.1
- Sanitation and Pest Control E1.1.1
- Sections 2.1.1 and 4.1.1
7 and 8 – Contamination of dough, rework and/or finished product with pathogenic microorganisms due to the addition of defective or suspect product that was not properly identified, controlled and/or isolated to prevent its use. Premises A2.1.1
- Transportation, Receiving and Storage B2.1.2
- Sections 1.8.1, 3.2.1 and 6.2.3
8 Sheeter/Former/Extruder – Contamination of dough, rework and/or finished product with pathogenic microorganisms due to inappropriately sourced and/or contaminated air used by equipment. Premises A2.3.3
- Section 3.2.3
9 Cooling/Drying – Contamination of dough and/or finished product from inappropriately sourced and/or contaminated air used by equipment for cooling and/or drying. Premises A2.3.3
- Section 3.2.3
9 Cooling/Drying – Growth of pathogenic microorganisms in dough and/or finished products due to ineffective cooling caused by equipment malfunction. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
13 Storage – Contamination of rework and/or unpackaged finished product in storage with pathogenic microorganisms due to failure to adequately separate from defective or suspect product and/or due to failure to identify, isolate and/or dispose of returned product. Premises A2.1.1
- Transportation, Receiving and Storage B2.1.2
- Sections 1.8.1, 3.2.1 and 6.2.3
13 Storage – Growth of pathogenic microorganisms in finished product due to elevated storage temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse). Transportation, Receiving and Storage B2.2.2
- Section 6.2.2
14 Shipping/Distribution – Contamination of finished product with pathogenic microorganisms as a result of loading product onto a carrier that is unacceptable for the transportation of food (e.g., carrier in unclean condition, carrier in poor state of repair). Transportation, Receiving and Storage B1.1.1
- Section 6.1.1
14 Shipping/Distribution – Contamination of finished product with pathogenic microorganisms as a result of transporting on same carrier with another non-ready-to-eat product (e.g., raw meat) or other product contaminated with pathogenic microorganisms. Transportation, Receiving and Storage B1.1.1 and B1.1.2
- Section 6.1.1
14 Shipping/Distribution – Contamination of finished product with pathogenic microorganisms as a result of improper loading/stacking resulting in damaged containers/packaging and exposure of finished products. Transportation, Receiving and Storage B1.1.1 and B1.1.2
- Section 6.1.1
Plant Schematic – Form 4 – B1 – Entrance to processing room and B2 – Entrance to packaging room – Cross contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished products and/or packaging materials with pathogenic microorganisms due to Improper employee hygiene procedures between rooms (i.e., improper use of foot dips / hand dips / change of clothing). (See Note below) Personnel D1.1.1 and D2.1.1
- Sections 5.1.1, 5.2.1 and 5.2.2
Plant Schematic – Form 4 – B1 – Entrance to processing room and B2 – Entrance to packaging room – Cross contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging material due to a failure to maintain the concentration of sanitizers in hand dips / foot dips at a level adequate to control pathogenic microorganisms. (See Note below) Premises  A2.1.1
- Sections 1.8.1 and 6.2.3

Note: The manufacturer should indicate the hazards using letters and/or numbers, e.g. B1 (for the first biological hazard identified on the Plant Schematic) and B2 (for the second biological hazard identified on the Plant Schematic), etc., and record each of the hazards on the Plant Schematic (Form 4) at the point where it occurs

Example of Completed Form 6: Chemical Hazards Identification

Product name: Fresh Non-Filled Alimentary Paste
List all chemical hazards related to ingredients, incoming material, processing, product flow, etc.
Identified chemical hazards Controlled at
Flour – Presence of nutrients (vitamins and minerals) above the maximum allowable limits in fortified flour. Transportation, Receiving and Storage B2.1.3 (of the FSEP Manual)
- Section 1.4.1 (of the guidance document)
Flour/spices/other ingredients – Presence of mycotoxins in flour, spices and/or other ingredients (e.g., vomitoxin in product made with wheat, aflatoxins and/or ochratoxin in spices and/or other ingredients). Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Flour/spices/other ingredients – Presence of undeclared allergens (e.g., wheat, soy and/or sulphites) in flour, spices and/or other ingredients. Transportation, Receiving and Storage B2.1.3
- Section 1.4.1
Flour/spices/other ingredients – Presence of food additives above the maximum allowable residue limits (e.g., ascorbic acid in flour, anti-caking agents and/or extraction solvents in spices and/or other ingredients). Transportation, Receiving and Storage B2.1.3
- Sections 1.1.4 and 1.4.1
Flour, spices, other ingredients – Presence of food additives (e.g. bromate in flour) and/or processing aids not permitted for use by government regulations in flour, spices and/or other ingredients. Transportation, Receiving and Storage B2.1.3
- Sections 1.1.4 and 1.4.1
Flour/ liquid whole egg (pasteurized)/ spices/ other ingredients – Presence of agricultural chemicals (e.g., pesticides, fumigants and herbicides) in flour, liquid whole egg (pasteurized), spices and/or other ingredients above the maximum allowable residue limits. Form 9
Liquid whole egg (pasteurized) – Presence of antibiotics in liquid whole egg (pasteurized) due to inappropriate use at farm level. Form 9
Liquid whole egg (pasteurized) – Presence of chemical residues (e.g., cleaning and sanitizing chemicals used to clean shell eggs prior to cracking) in liquid whole egg (pasteurized) due to inappropriate use at farm or supplier level. Form 9
Liquid whole egg (pasteurized) – Contamination of liquid whole egg (pasteurized) with non-food chemicals due to improper use of reusable food containers at supplier level. Form 9
Liquid whole egg (pasteurized) – Presence of mycotoxins in liquid whole egg (pasteurized) at levels significant to food safety due to inappropriate handling at the supplier level. Not likely to occur in excess of the acceptable food safety levels.
Water/well water – Not meeting the Guidelines for Canadian Drinking Water Quality published by Health Canada as well as any provincial or municipal requirements. Premises A4.1.1 and A4.1.2
- Sections 3.4.1 and 7.4.1
Spices – Excess levels of ethylene chlorohydrin (FDR, Division 16, Table VIII, Ethylene Oxide) in spices. Transportation, Receiving and Storage B2.1.3
- Sections 1.1.4 and 1.4.1
Spices – Presence of by-products in spices resulting from over irradiation or improper irradiation procedures at the supplier level. Form 9
Spices/ other ingredients – Contamination of spices and/or other ingredients with agricultural chemicals and/or non-food chemicals due to improper use of reusable food containers at the supplier level/treatment facility. Form 9
Packaging Materials – Not food grade and/or not appropriate for intended use. Transportation, Receiving and Storage B2.1.3
- Section 1.4.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues as a result of improper usage of non-food chemicals. Sanitation and Pest Control E1.1.1; Equipment C1.2.1
- Sections 4.1.1, 2.1.3 and 2.1.4
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues as a result of improper storage of non-food chemicals. Transportation, Receiving and Storage B2.2.2 and B2.2.3
- Sections 6.2.1 and 6.2.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues as a result of improper handling of non-food chemicals by employees. Personnel D1.1.1 and D2.1.1; Transportation, Receiving and Storage B2.2.3
- Sections 5.1.1, 5.2.1 , 5.2.2 and 6.2.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues as a result of improper sanitation procedures. Sanitation and Pest Control E1.1.1
- Section 4.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished products and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues during sanitation procedures as a result of damaged containers or packaging material and/or open containers resulting in exposed product. Sanitation and Pest Control E1.1.1
- Transportation, Receiving and Storage B2.2.2
- Sections 1.5.1, 4.1.1, 6.2.1, 6.2.2 and 6.2.3
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with undeclared allergens as a result of improper employee handling procedures. Personnel D1.1.1, D1.2.1 and D2.1.1
- Sections 5.1.1, 5.2.1 and 5.2.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteruized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals (e.g., lubricants, oil and/or hydraulic fluid) as a result of poor equipment design. Equipment C1.1.1
- Sections 2.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals (e.g., lubricants, oil and/or hydraulic fluid) as a result of improper equipment maintenance. Equipment C1.2.1
- Sections 2.1.3 and 2.1.4
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with non-food chemicals due to inadequate separation of product handling and packaging areas from equipment cleaning and sanitizing facilities. Premises A2.1.1
- Section 3.3.2
1 Receiving – Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient. -Transportation, Receiving and Storage B2.1.3
- Personnel D1.2.1
- Sections 1.1.4, 1.4.1, 1.4.2 and 5.2.2
1 Receiving – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging materials with non-food chemicals being received at the same time as other ingredients and/or packaging materials. Transportation, Receiving and Storage B2.2.3
- Personnel D1.2.1
- Section 5.2.2 and 6.2.2
2, 6, 7, 8, 9, 10, 11, 12 – Cross contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with undeclared food allergens (e.g. wheat, soy) not declared on the list of ingredients due to:
  • failure to use dedicated equipment and utensils and/or
  • failure to clean equipment, tools and/or utensils between product that contain allergens and products that do not and/or
  • failure of employees to follow proper sanitation procedures resulting in inadequate equipment cleanout.
Premises A2.1.1 –
Sanitation and Pest Control E1.1.1
- Personnel D1.2.1
- Sections 1.8.1, 4.1.1, 5.2.2 and 6.2.3
2, 6, 7, 8, 9, 10, 11 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with allergens (e.g. wheat, soy) from one production line to an adjoining line due to inadequate facility design resulting in inadequate separation. Premises A2.1.1
- Sections 1.8.1and 6.2.3
2, 6, 7, 8, 9, 10, 11 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with allergens (e.g. wheat, soy) from one production line to an adjoining line due to inadequate training of employees. Personnel D1.1.1 and D2.1.1
- Sections 5.1.1, 5.2.1 and 5.2.2
2, 6, 7, 8, 9, 10, 11 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with allergens (e.g. wheat, soy) from one production line to an adjoining line due to improper sanitation procedures. Sanitation and Pest Control E1.1.1
- Section 4.1.1
2, 6, 7, 8, 9, 10, 11 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with allergens (e.g. wheat, soy) from one production line to an adjoining line due to cross utilization of scoops, utensils and/or equipment between products and/or between product lines. Premises A2.1.1; Personnel D1.1.1 and D2.1.1
- Sections 1.8.1, 5.1.1, 5.2.1, 5.2.2 and 6.2.3
2, 3, 4 – Contamination of non-allergen containing flour, spices, other ingredients and/or liquid whole egg (pasteurized) with allergens due to inadequate separation from allergens or product containing allergens in storage. Premises A2.1.1
- Transportation, Receiving and Storage B2.2.2
- Sections 1.8.1 and 6.2.3
2 Flour Storage – Contamination of non-allergen containing flour with undeclared allergen as a result of storing in silo where flour containing allergens (e.g., wheat, soy) was previously stored. Premises A2.1.1
- Transportation, Receiving and Storage B2.2.2
- Sanitation and Pest Control E1.1.1
- Sections 1.8.1, 4.1.1 and 6.2.3
6, 7, 8, 9, 10, 11, 12 – Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with heavy metals (e.g., lead) and/or other chemicals due to use of non-food grade food contact surfaces for equipment and/or utensils. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
7 Ingredient Weighing/ Measuring/ Mixing – Contamination of dough and/or finished products with undeclared food allergens due to the incorrect addition of allergens (or their derivatives) or rework containing allergens (or their derivatives) that do not appear in the formulation/recipe. CCP-1C
7 Ingredient Weighing/ Measuring/ Mixing – Contamination of dough and/or finished products with undeclared food allergens due to failure to control dust containing allergens. Premises A2.3.1
- Equipment C1.1.1 and C1.2.1
- Sections 2.1.1, 2.1.3 and 3.2.3
7 Ingredient Weighing/ Measuring/ Mixing – Contamination of dough and finished products with undeclared food allergens (or their derivatives) due to ingredient changes, substitutions and/or additions resulting in the presence of allergens that do not appear on the label. CCP-1C
9 Cooling/ Drying – Contamination of finished product with non-food chemicals (e.g., refrigerant). Premises A2.1.1 and A2.3.3
- Equipment C1.1.1 and C1.2.1
- Sections 2.1.1, 2.1.3, 3.2.1 and 3.2.3
11 Weighing/ Packaging/ Labelling/ Coding – Presence of undeclared allergens (e.g., wheat, soy, eggs) in the finished product due to incorrect label application, use of incorrect packaging, use of incorrect list of ingredients and/or use of illegible list of ingredients on the label. CCP-2C
11 Weighing/ Packaging/ Labelling/ Coding – Contamination of finished product with inks/solvents as a result of equipment that is not properly maintained and/or set up. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
11 Weighing/ Packaging/ Labelling/ Coding – Contamination of finished product with inks/solvents as a result of improper storage of inks/solvents. Transportation, Receiving and Storage B2.2.3
- Section 6.2.3
14 Shipping/ Distribution – Contamination of finished product with non-compatible goods carried on the same transport vehicle (i.e. non-food or food grade chemicals). Transportation, Receiving and Storage B1.1.1
- Section 6.1.1
Plant Schematic – Form 4 – Cross contamination of flour, spices, other ingredients, rework, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials due to improper employee hygienic procedures at entrance to rooms and/or between production lines resulting in allergenic contamination (i.e., improper use of foot dips/hand dips/change of clothing). (See Note below) Personnel D1.1.1 and D2.1.1
- Sections 5.1.1, 5.2.1 and 5.2.2

Note: The manufacturer should indicate the hazards using letters and/or numbers, e.g. C1 (for the first chemical hazard identified on the Plant Schematic) and C2 (for the second chemical hazard identified on the Plant Schematic), etc., and record each of the hazards on the Plant Schematic (Form 4) at the point where it occurs

Example of Completed Form 7: Physical Hazards Identification

Product name: Fresh Non-Filled Alimentary Paste
List all chemical hazards related to ingredients, incoming material, processing, product flow, etc.
Identified chemical hazards Controlled at
Flour/ Liquid whole egg (pasteurized)/ Spices/ other ingredients/ Packaging Materials – Presence of hazardous extraneous material (metallic and/or non-metallic) due to improper processing and/or handling at the supplier level and/or during transportation. Transportation, Receiving and Storage B2.1.3 (of the FSEP Manual)
- Section 1.4.1 (of the guidance document)
Water/well water – Presence of hazardous extraneous material in water/well water (metallic and/or non-metallic). Premises A4.1.1 and A4.14
- Sections 3.4.1 and 7.4.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with hazardous extraneous material (metallic and/or non-metallic) as a result of dirty or poorly maintained overhead structures. Premises A2.1.1 and A2.1.2; Sanitation and Pest Control E1.1.1
- Sections 2.1.3, 3.2.1 and 4.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with hazardous extraneous material (metallic and/or non-metallic) as a result of improper equipment maintenance procedures. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 – Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with metallic and/or non-metallic hazardous extraneous material (i.e. metal, wood, glass, plastic) due to improper employee handling. Personnel D1.1.1 and D2.1.1
- Sections 5.1.1, 5.2.1 and 5.2.2
1 Receiving – Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient. Transportation, Receiving and Storage B2.1.3
- Personnel D1.2.1
- Sections 1.1.4, 1.4.1, 1.4.2 and 5.2.2
6, 7, 8, 9, 10, 11 – Presence of metallic and/or non-metallic hazardous extraneous material (e.g., metal shavings, plastic) in dough, rework and/or finished product due to deterioration of food contact surfaces (including tools, utensils and/or equipment surfaces). Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
6, 7, 8, 9, 10 – Contamination of dough and/or finished product with metallic and/or non-metallic hazardous extraneous material (e.g., metal shavings) due to poor equipment design, improper installation,, improper or inadequate equipment maintenance procedures, wear and tear on equipment, equipment deterioration and/or poor machine set up. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
6, 7, 8, 9, 10 – Contamination of dough and/or finished product with metallic and/or non-metallic hazardous extraneous material (e.g. metal shavings) due to rubbing of metal on equipment parts. Equipment C1.1.1 and C1.2.1
- Sections 2.1.1 and 2.1.3
6 Sifting/ Screening – Presence of hazardous extraneous material (metallic and/or non-metallic) in flour, dough and/or finished product due to accumulation of hazardous extraneous material on sifter/screen and/or damage to sifter/screen as a result of inadequate cleaning and/or inspection. Equipment C1.1.1 and C1.2.1
- Sanitation and Pest Control E1.1.1
- Sections 2.1.1, 2.1.3 and 4.1.1
12 Metal Detector – Presence of hazardous extraneous material (metallic) in finished product due to improper calibration. Equipment C1.2.2
- Sections 2.1.3 and 2.1.4
12 Metal Detector – Presence of hazardous extraneous material (metallic) in finished product due to failure of the metal detector to detect metal. CCP-3P
12 Metal Detector – Presence of hazardous extraneous material (metallic) in finished product due to failure of the metal detector to function as intended when metal is detected (i.e. line stops, alarm sounds, product is kicked off the line). CCP-3P
14 Shipping/ Distribution – Contamination of finished product with metallic and non-metallic hazardous extraneous material due to unacceptable condition of transportation vehicle. Transportation, Receiving and Storage B1.1.1 and B1.1.2
- Section 6.1.1
14 Shipping/ Distribution – Contamination of finished product with metallic and non-metallic hazardous extraneous material due to improper loading and arranging procedures resulting in damaged or exposed product. Transportation, Receiving and Storage B1.1.2
- Section 6.1.1

Example of Completed Form 8: CCP Determination

Product name: Fresh Non-Filled Alimentary Paste
Incoming materials/process steps/hazards on schematic diagram Category and identified hazard
Determine if fully controlled by prerequisite program.
* If yes = indicate "Prerequisite Program" and proceed to next identified hazard.
* If no = proceed to question 1 (Q1).
Q1. Could a control measure(s) be used by the operator at any process step?
* If no = not a CCP. Identify how this hazard will be controlled before and after the process. Then proceed to the next identified hazard.
* If yes = describe the measure and proceed to Q2.
Q2. Is it likely that contamination with the identified hazard could occur in excess of the acceptable level or could increase to an unacceptable level?
* If no = not a CCP. Proceed to the next identified hazard.
* If yes = proceed to Q3.
Q3. Is this process specifically designed to eliminate or reduce the likely occurrence of the identified hazard to an acceptable level?
* If no = proceed to Q4.
* If yes = CCP. Enter its number in the last column.
Q4. Will a subsequent step eliminate the identified hazard or reduce its likely occurrence to an acceptable level?
* If no = CCP. Enter its number in the last column.
* If yes = not a CCP. Identify subsequent (controlling) step and proceed to the next identified hazard.
CCP number
* Proceed to next identified hazard.
Flour Biological
Presence of Bacillus cereus in flour at levels significant to food safety.
No
No No,
Not likely to occur in excess of the acceptable food safety levels
Flour Biological
Presence of Salmonella spp. in flour.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour Chemical
Presence of nutrients (vitamins and minerals) above the maximum allowable limits in fortified flour.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour/ spices/ other ingredients Chemical
Presence of mycotoxins in flour, spices and/or other ingredients (e.g. vomitoxin in product made with wheat, aflatoxins and/or ochratoxin in spices and/or other ingredients).
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour/ spices/ other ingredients Chemical
Presence of undeclared allergens (e.g., wheat soy and/or sulphites) in flour, spices and/or other ingredients.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour/ spices/ other ingredients Chemical
Presence of food additives (e.g., bromate in flour) and/or processing aids not permitted for use by government regulations in flour, spices and/or other ingredients.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour/ spices/ other ingredients Chemical
Presence of food additives (e.g., bromate in flour) and/or processing aids not permitted for use by government regulations in flour, spices and/or other ingredients.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Flour/ liquid whole egg (pasteurized)/ spices/ other ingredients Chemical
Presence of agricultural chemicals (e.g., pesticides, fumigants and herbicides) in flour, liquid whole egg (pasteurized), spices and/or other ingredients above the maximum allowable residue limits.
No
No
Form 9
Flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging material Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging material with pathogenic microorganisms during transportation due to unclean/damaged packaging and/or unclean/damaged vehicles used for transportation from supplier to manufacturer.
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.1.1 and B2.1.3
Flour/ Liquid whole egg (pasteurized)/ Spices/ other ingredients/ packaging materials Physical
Presence of hazardous extraneous material (metallic and/or non-metallic) due to improper processing and/or handling at the supplier level and/or during transportation.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Liquid whole egg (pasteurized) Biological
Growth of sporulating pathogenic bacteria due to elevated storage temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse) at the supplier level and/or during transportation.
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.2.1 and B2.1.3
Liquid whole egg (pasteurized) Biological
Presence of pathogenic bacteria (e.g., Salmonella spp., Listeria monocytogenes) due to ineffective pasteurization and/or improper handling procedures at the supplier level.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Liquid whole egg (pasteurized) Chemical
Presence of antibiotics in liquid whole egg (pasteurized) due to inappropriate use at farm level.
No
No
Form 9
Liquid whole egg (pasteurized) Chemical
Presence of chemical residues (e.g. cleaning and sanitizing chemicals used to clean shell eggs prior to cracking) in liquid whole egg (pasteurized) due to inappropriate use at farm or supplier level.
No
No
Form 9
Liquid whole egg (pasteurized) Chemical
Contamination of liquid whole egg (pasteurized) with non-food chemicals due to improper use of reusable food containers at supplier level.
No
No
Form 9
Liquid whole egg (pasteurized) Chemical
Presence of mycotoxins in liquid whole eggs (pasteurized) at levels significant to food safety due to inappropriate handling at the supplier level.
No
No No,
Not likely to occur in excess of the acceptable food safety levels.
Water/well water Biological/Chemical
Not meeting the Guidelines for Canadian Drinking Water Quality published by Health Canada as well as any provincial or municipal requirements.
Yes
Prerequisite Program
Premises A4.1.1 and 4.1.2
Water/well water Physical
Presence of hazardous extraneous material in water/well water (metallic and/or non-metallic).
Yes
Prerequisite Program
Premises A4.1.1 and A4.14
Spices Biological
Presence of pathogenic microorganisms due to inadequate antimicrobial treatment.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Spices Chemical
Excess levels of ethylene chlorohydrin (FDR, Division 16, Table VIII, Ethylene Oxide) in spices.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Spices Chemical
Presence of by-products in spices resulting from over irradiation or improper irradiation procedures at the supplier level.
No
Form 9
Spices/ other ingredients Biological
Presence of pathogenic microorganisms in spices and/or other ingredients due to improper handling at the supplier level.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Spices/ other ingredients Chemical
Contamination of spices and/or other ingredients with agricultural chemicals and/or non-food chemicals due to improper use of reusable food containers at the supplier /treatment facility.
No
No
Form 9
Packaging Material Biological
Presence of pathogenic microorganisms on packaging material due to damage or soiling as a result of mishandling at the supplier level.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Packaging Materials Biological
Presence of pathogenic microorganisms due to contamination with faecal material from pests (rodents, birds and insects).
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
Packaging Materials Chemical
Not food grade and/or not appropriate for intended use.
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.3
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to improper employee hygiene and handling.
Yes
Prerequisite Program
Personnel D1.1.1 and D2.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to contamination from overhead structures (e.g., leaking pipes).
Yes
Prerequisite Programs
Premises A2.1.2 and A2.3.1
Sanitation and Pest Control E1.1.1
Equipment C1.1.1 and C1.2.1
1, 4, 7, 8, 9, 10, 11, 12, 14 Biological
Growth of pathogenic microorganisms in liquid whole egg (pasteurized), rework, dough and/or finished product due to exposure to elevated room temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse).
Yes
Prerequisite Programs
Transportation, Receiving and Storage B2.1.1, B2.1.2 and B2.2.2
Equipment C1.2.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with pathogenic microorganisms due to contact with pests (flies, rodents, birds).
Yes
Prerequisite Program
Sanitation and Pest Control E2.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms as a result of exposed product due to:
  1. improper storage procedures and/or
  2. improper employee hygiene and handling.
Yes
Prerequisite Programs
  1. Transportation, Receiving and Storage B2.1.2 and B2.2.2
  2. Personnel D1.1.1 and D2.1.1
1, 2, 3, 4, 6, 7, 8, 9, 10, 11, 12 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms due to contact with unclean tools, utensils & equipment as a result of improper sanitation procedures.
Yes
Prerequisite Program
Sanitation and Pest Control E1.1.1
1, 6, 7, 8, 9, 10, 11, 12 Biological
Contamination of dough, rework, finished product and/or packaging material with pathogenic microorganisms due to inadequate separation of production and packaging areas from facilities for equipment cleaning and sanitizing.
Yes
Prerequisite Program
Premises A2.2.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Chemical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues as a result of:
  1. improper usage of non-food chemicals and/or
  2. improper storage of non-food chemicals and/or
  3. improper handling of non-food chemicals by employees and/or
  4. improper sanitation procedures.
Yes
Prerequisite Programs
  1. Sanitation and Pest Control E1.1.1; Equipment C1.2.1
  2. Transportation, Receiving and Storage B2.2.2 and B2.2.3
  3. Personnel D1.1.1 and D2.1.1; Transportation, Receiving and Storage B2.2.3
  4. Sanitation and Pest Control E1.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Chemical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished products and/or packaging materials with non-food chemicals, cleaning solutions, sanitizers and/or their residues during sanitation procedures as a result of damaged containers or packaging material, and/or open containers resulting in exposed product.
Yes
Prerequisite Programs:
Sanitation and Pest Control E1.1.1
Transportation, Receiving and Storage B2.2.2
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Chemical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with undeclared allergens as a result of improper employee handling procedures.
Yes
Prerequisite Program
Personnel D1.1.1, D1.2.1 and D2.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Chemical
Contamination of flour, liquid whole egg (pasteruized), spices, other ingredients, dough, rework, finished product and/or packaging materials with non-food chemicals (e.g., lubricants, oil and/or hydraulic fluid) as a result of:
  1. poor equipment design and/or
  2. improper equipment maintenance.
Yes
Prerequisite Programs
  1. Equipment C1.1.1
  2. Equipment C1.2.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Chemical
Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with non-food chemicals due to inadequate separation of product handling and packaging areas from equipment cleaning and sanitizing facilities.
Yes
Prerequisite Program
Premises A2.1.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 Physical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with hazardous extraneous material (metallic and/or non-metallic) as a result of:
  1. dirty or poorly maintained overhead structures and/or
  2. improper equipment maintenance procedures.
Yes
Prerequisite Programs
  1. Premises A2.1.1 and A2.1.2
    - Sanitation and Pest Control E1.1.1
  2. Equipment C1.1.1 and C1.2.1
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 Physical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, packaging materials and/or finished product with metallic and/or non-metallic hazardous extraneous material (i.e. metal, wood, glass, plastic) due to improper employee handling.
Yes
Prerequisite Program
Personnel D1.1.1 and D2.1.1
1 Receiving Biological
Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient.
Yes
Prerequisite Programs
Transportation, Receiving and Storage B1.1.1 and B2.1.3
Personnel D1.2.1
1 Receiving Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, and/or packaging material with pathogenic microorganisms from contaminated raw products (non-ready-to-eat) carried on the same truck.
Yes
Prerequisite Programs
Transportation, Receiving and Storage B1.1.1 and B2.1.3
Personnel D1.2.1
1 Receiving Biological
Contamination of dough, rework and/or finished product due to failure to properly identify, isolate and/or dispose of returned product when received.
Yes
Prerequisite Programs
Premises A2.1.1
Transportation, Receiving and Storage B2.1.2
Personnel D1.2.1
1 Receiving Chemical
Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient.
Yes
Prerequisite Programs
Transportation, Receiving and Storage B2.1.3
Personnel D1.2.1
1 Receiving Chemical
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients and/or packaging materials with non-food chemicals being received at the same time as other ingredients and/or packaging materials.
Yes
Prerequisite Programs
Transportation, Receiving and Storage B2.2.3
Personnel D1.2.1
1 Receiving Physical
Acceptance of incoming materials and ingredients not meeting specifications (i.e. not meeting firm's standards) as described on specification sheets for each incoming material and/or ingredient.
Yes
Prerequisite Programs
Transportation, Receiving and Storage B2.1.3
Personnel D1.2.1
2, 3, 4, 5, 6, 7, 8, 9, 10, 11 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging materials with pathogenic microorganisms due to contaminated room air.
Yes
Prerequisite Programs
Premises A2.1.1 and A2.3.1
2, 6, 7, 8, 9, 10, 11, 12 Chemical
Cross contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with undeclared food allergens (e.g. wheat, soy) not declared on the list of ingredients due to:
  • failure to use dedicated equipment and utensils and/or
  • failure to clean equipment, tools and/or utensils between products that contain allergens and products that do not and/or
  • failure of employees to follow proper sanitation procedures resulting in inadequate equipment cleanout.
Yes
Prerequisite Programs
Premises A2.1.1
Sanitation and Pest Control E1.1.1
Personnel D1.2.1
2, 6, 7, 8, 9, 10, 11 Chemical
Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with allergens (e.g. wheat, soy) from one production line to an adjoining line due to:
  1. inadequate facility design resulting in inadequate separation and/or
  2. inadequate training of employees and/or
  3. improper sanitation procedures and/or
  4. cross utilization of scoops, utensils and/or equipment between products and/or between product lines.
Yes
Prerequisite Programs
  1. Premises A2.1.1
  2. Personnel D1.1.1 and D2.1.1
  3. Sanitation and Pest Control E1.1.1
  4. Premises A2.1.1; Personnel D1.1.1 and D2.1.1
2, 3, 4 Chemical
Contamination of non-allergen containing flour, spices, other ingredients and/or liquid whole egg (pasteurized) with allergens due to inadequate separation from allergens or product containing allergens in storage.
Yes
Prerequisite Programs
Premises A2.1.1
Transportation, Receiving and Storage B2.2.2
2 Flour Storage Chemical
Contamination of non-allergen containing flour with undeclared allergen as a result of storing in silo where flour containing allergens (e.g., wheat, soy) was previously stored.
Yes
Prerequisite Programs
Premises A2.1.1
Transportation, Receiving and Storage B2.2.2
Sanitation and Pest Control E1.1.1
4 Liquid Whole Egg (Pasteurized) Storage Biological
Growth of pathogenic microorganisms in liquid whole egg (pasteurized) in storage due to failure to rotate incoming product (first in, first out).
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.1.2
4 Liquid Whole Egg (Pasteurized) Storage Biological
Growth of pathogenic microorganisms in liquid whole egg (pasteurized) due to elevated storage temperatures (e.g., above 4°C) for an extended period of time (time/temperature abuse).
Yes
Prerequisite Programs
Transportation, Receiving and Storage B2.1.1 and B2.1.2
Equipment C1.2.1
6, 7, 8, 9, 10, 11 Biological
Contamination of subsequent lots/batches of dough and/or finished product with pathogenic microorganisms due to failure to adequately clean product residue from machinery between lots/batches/products.
Yes
Prerequisite Programs
Sanitation and Pest Control E1.1.1
Personnel D1.2.1
6, 7, 8, 9, 10, 11 Biological
Contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished products and/or packaging materials due to presence of pathogenic microorganisms on damaged and/or deteriorating surfaces of equipment, conveyors, tools and/or utensils (i.e., presence of pathogenic microorganisms in cracks and crevices).
Yes
Prerequisite Programs
Equipment C1.1.1 and C1.2.1
Sanitation E1.1.1
6, 7, 8, 9, 10, 11, 12 Chemical
Contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials with heavy metals (e.g., lead) and/or other chemicals due to use of non-food grade food contact surfaces for equipment and/or utensils.
Yes
Prerequisite Program
Equipment C1.1.1 and C1.2.1
6, 7, 8, 9, 10, 11 Physical
Presence of metallic and/or non-metallic hazardous extraneous material (e.g., metal shavings, plastic) in dough, rework and/or finished product due to deterioration of food contact surfaces (including tools, utensils and/or equipment surfaces).
Yes
Prerequisite Program
Equipment C1.1.1 and C1.2.1
6, 7, 8, 9, 10 Physical
Contamination of dough and/or finished product with metallic and/or non-metallic hazardous extraneous material (e.g., metallic shavings) due to poor equipment design, improper installation, improper or inadequate equipment maintenance procedures, wear and tear on equipment, equipment deterioration and/or poor machine set up.
Yes
Prerequisite Program
Equipment C1.1.1 and C1.2.1
6, 7, 8, 9, 10 Physical
Contamination of dough and/or finished product with metallic and/or non-metallic hazardous extraneous material (e.g. metal shavings) due to rubbing of metal on equipment parts.
Yes
Prerequisite Program
Equipment C1.1.1 and C1.2.1
6 Sifting/ Screening Physical
Presence of hazardous extraneous material (metallic and/or non-metallic) in flour, dough and/or finished product due to accumulation of hazardous extraneous material on sifter/screen and/or damage to sifter/screen as a result of inadequate cleaning and/or inspection.
Yes
Prerequisite Programs
Equipment C1.1.1 and C1.2.1
Sanitation and Pest Control E1.1.1
7, 8, 9, 10, 11, 12 Biological
Contamination of dough, rework and/or finished product with pathogenic microorganisms present at specific points in the process where improper line design, improper equipment design and/or incomplete cleaning allow product and/or moisture to accumulate (e.g., improper welds, dead end pipes, sharp angles).
Yes
Prerequisite Programs
Equipment C1.1.1
Sanitation and Pest Control E1.1.1
7 and 8 Biological
Contamination of dough, rework and/or finished product with pathogenic microorganisms due to the addition of defective or suspect product that was not properly identified, controlled and/or isolated to prevent its use.
Yes
Prerequisite Programs
Premises A2.1.1
Transportation, Receiving and Storage B2.1.2
7 Ingredient Weighing/ Measuring/ Mixing Chemical
Contamination of dough and/or finished products with undeclared food allergens due to the incorrect addition of allergens (or their derivatives) or rework containing allergens (or their derivatives) that do not appear in the formulation/recipe.
No
Yes
Monitoring the addition of all ingredients including rework.
Yes Yes CCP-1C
7 Ingredient Weighing/ Measuring/ Mixing Chemical
Contamination of dough and/or finished products with undeclared food allergens due to failure to control dust containing allergens.
Yes
Prerequisite Programs
Premises A2.3.1
Equipment C1.1.1 and C1.2.1
7 Ingredient Weighing/ Measuring/ Mixing Chemical
Contamination of dough and/or finished products with undeclared food allergens (or their derivatives) due to ingredient changes, substitutions and/or additions resulting in the presence of allergens that do not appear on the label.
No
Yes
The manufacturer can monitor the addition of ingredients including rework.
Yes Yes CCP-1C
8 Sheeter/ Former/ Extruder Biological
Contamination of dough, rework and/or finished product with pathogenic microorganisms due to inappropriately sourced and/or contaminated air used by equipment.
Yes
Prerequisite Program
Premises A2.3.3
9 Cooling/ Drying Biological
Contamination of dough and/or finished product from inappropriately sourced and/or contaminated air used by equipment for cooling and/or drying.
Yes
Prerequisite Program
Premises A2.3.3
9 Cooling/ Drying Biological
Growth of pathogenic organisms in dough and/or finished products due to ineffective cooling caused by equipment malfunction.
Yes
Prerequisite Program
Equipment C1.1.1 and C1.2.1
9 Cooling/ Drying Chemical
Contamination of finished product with non-food chemicals (e.g., refrigerant).
Yes
Prerequisite Programs
Premises A2.1.1 and A2.3.3
Equipment C1.1.1 and C1.2.1
11 Weighing/ Packaging/ Labelling/ Coding Chemical
Presence of undeclared allergens (e.g. wheat, soy, eggs) in the finished product due to incorrect label application, use of incorrect packaging, use of incorrect list of ingredients and/or use of illegible list of ingredients on the label.
No
Yes,
Monitoring the application of the correct label with the correct list of ingredients.
Yes Yes CCP-2C
11 Weighing/ Packaging/ Labelling/ Coding Chemical
Contamination of finished product with inks/solvents as a result of
  1. equipment that is not properly maintained and/or set up and/or
  2. improper storage of inks/solvents.
Yes
Prerequisite Programs
  1. Equipment C1.1.1 and C1.2.1
  2. Transportation, Receiving and Storage B2.2.3
12 Metal Detector Physical
Presence of hazardous extraneous material (metallic) in finished product due to improper calibration.
Yes
Prerequisite Program
Equipment C1.2.2
12 Metal Detector Physical
Presence of hazardous extraneous material (metallic) in finished product due to failure of the metal detector to detect metal.
No
Yes,
Monitor the metal detector using test wands to ensure it is able to detect metal.
Yes Yes CCP-3P
12 Metal Detector Physical
Presence of hazardous extraneous material (metallic) in finished product due to failure of the metal detector to function as intended when metal is detected (i.e. line stops, alarm sounds, product is kicked off the line).
No
Yes,
Monitor the metal detector using test wands to ensure it is functioning properly when metal is detected.
Yes Yes CCP-3P
13 Storage Biological
Contamination of rework and/or unpackaged finished product in storage with pathogenic microorganisms due to failure to adequately separate from defective or suspect product and/or due to failure to identify, isolate and/or dispose of returned product.
Yes
Prerequisite Programs
Premises A2.1.1
Transportation, Receiving and Storage B2.1.2
13 Storage Biological
Growth of pathogenic microorganisms in finished product due to elevated storage temperatures (e.g. above 4°C) for an extended period of time (time/temperature abuse).
Yes
Prerequisite Program
Transportation, Receiving and Storage B2.2.2
14 Shipping/ Distribution Biological
Contamination of finished product with pathogenic microorganisms as a result of loading product onto a carrier that is unacceptable for the transportation of food (e.g., carrier in unclean condition, carrier in poor state of repair).
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.1.1
14 Shipping/ Distribution Biological
Contamination of finished product with pathogenic microorganisms as a result of transporting on same carrier with another non-ready-to-eat product (e.g., raw meat) or other product contaminated with pathogenic microorganisms.
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.1.1 and B1.1.2
14 Shipping/ Distribution Biological
Contamination of finished product with pathogenic microorganisms as a result of improper loading/stacking resulting in damaged containers/packaging and exposure of finished products.
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.1.2 and B1.1.2
14 Shipping/ Distribution Chemical
Contamination of finished product with non-compatible goods carried on the same transport vehicle (i.e. non-food or food grade chemicals).
Yes
Prerequisite Program
Transportation, Receiving and Storage B1.1.1
14 Shipping/ Distribution Physical
Contamination of finished product with metallic and non-metallic hazardous extraneous material due to:
  1. unacceptable condition of transportation vehicle and/or
  2. improper loading and arranging procedures resulting in damaged or exposed product.
Yes
Prerequisite Programs
  1. Transportation, Receiving and Storage B1.1.1 and B1.1.2
  2. Transportation, Receiving and Storage B1.1.2
Plant Schematic - Form 4 - B1 - Entrance to processing room and B2 - Entrance to packaging room Biological
Cross contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, rework, finished products and/or packaging materials with pathogenic microorganisms due to improper employee hygiene procedures between rooms (i.e., improper use of foot dips/ hand dips/ change of clothing).
Yes
Prerequisite Program
Personnel D1.1.1 and D2.1.1
Plant Schematic - Form 4 - B1 - Entrance to processing room and B2 - Entrance to packaging room Biological
Cross contamination of flour, liquid whole egg (pasteurized), spices, other ingredients, dough, rework, finished product and/or packaging material due to a failure to maintain the concentration of sanitizers in hand dips/ foot dips at a level adequate to control pathogenic microorganisms.
Yes
Prerequisite Program
Premises A2.1.1
Schematic - Form 4 - C1 - Entrance to processing room and C2 - Entrance to packaging room Chemical
Cross contamination of flour, spices, other ingredients, liquid whole egg (pasteurized), dough, rework, finished product and/or packaging materials due to improper employee hygienic procedures at entrance to rooms and/or between production lines resulting in allergenic contamination (i.e., improper use of foot dips/ hand dips/ change of clothing).
Yes
Prerequisite Program
Personnel D1.1.1 and D2.1.1

Example of Completed Form 9: Hazards not controlled by the Operator

Product name: Fresh Non-Filled Alimentary Paste
List here any biological, chemical and physical hazards that are not controlled by the operator
Hazards Indicate how the hazard could be addressed (cooking instructions, public education, "use before" date, etc.)
Flour/ liquid whole egg (pasteurized)/ spices/ other ingredients - Presence of agricultural chemicals (e.g., pesticides, fumigants and herbicides) in flour, liquid whole egg (pasteurized), spices and/or other ingredients above the maximum allowable residue limits. Education of farmers about Good Agricultural Practices (GAP) and correct use of agricultural chemicals.
Liquid whole egg (pasteurized) - Presence of antibiotics in liquid whole egg (pasteurized) due to inappropriate use at farm level. Education of farmers about antibiotic use and GAP.
Liquid whole egg (pasteurized) - Presence of chemical residues (e.g. cleaning and sanitizing chemicals used to clean shell eggs prior to cracking) in liquid whole egg (pasteurized) due to inappropriate use at farm or supplier level. Education of farmers and/or suppliers (egg cracking stations) in GAP, proper chemical use and rinsing of eggs prior to cracking.
Liquid whole egg (pasteurized) - Contamination of liquid whole egg (pasteurized) with non-food chemicals due to improper use of reusable food containers at supplier level. Education of supplier and/or regular supplier audits.
Spices - Presence of by-products in spices, resulting from over irradiation or improper irradiation procedures at the supplier level. Education of treatment facility
Spices/ other ingredients - Contamination of spices and/or other ingredients with agricultural chemicals and/or non-food chemicals due to improper use of reusable food containers at supplier/treatment facility. Education of supplier about GAP and/or regular supplier audits.

Example of Completed Form 10: HACCP Plan - Critical Control Points

Product name: Fresh Non-Filled Alimentary Paste
Process Steps CCP/Hazard Number Hazard Description Critical Limits Monitoring Procedures Deviation Procedures Verification Procedures HACCP Records
7 Ingredient Weighing/ Measuring/ Mixing CCP-1C

Contamination of dough and/or finished products with undeclared food allergens due to the incorrect addition of allergens (or their derivatives) or rework containing allergens (or their derivatives) that do not appear in the formulation/ recipe.

Contamination of dough and/or finished products with undeclared food allergens (or their derivatives) due to ingredient changes, substitutions and/or additions resulting in the presence of allergens that do not appear on the label.

Only those ingredients (including rework) identified on the recipe and/or formulation are added to the mixer for each batch of product as per the SOP CCP-1C Product Formulations and Recipes following procedures as indicated in the SOP for Weighing/ Mixing Products.

A facility employee is responsible for weighing, measuring and batching the ingredients as per SOP for Weighing/Mixing Products.

For each batch of weighed ingredients, the CCP-1C Monitor compares the ingredients to the recipe for that product to ensure that the batched ingredients (including rework) provided by the facility employee are the same as what is indicated in the SOP CCP-1C Product Formulations and Recipes for the product being manufactured.

As the CCP-1C Monitor adds each ingredient to the mixer (as indicted in the SOP CCP-1C Product Formulations and Recipes) records each ingredient on the CCP-1C Monitoring Record. Signs and dates the CCP-1C Monitoring Record and records the time the monitoring was completed.

If CCP-1C Monitor identifies any discrepancies in the batched ingredients the CCP-1C Monitor does not add the incorrect ingredient to the mixer and/or if an ingredient has been added to the mixer incorrectly, places batch on Hold as per Hold procedures and notifies CCP-1C Authorized Person. Records the description of the deviation and corrective actions taken, including time completed on CCP-1C Monitoring Record. Signs and dates.

CCP-1C Authorized Person places all affected product on hold as per Hold Procedures and makes an assessment as to whether food safety has been compromised as per written Food Safety Assessment Procedures. If food safety has been compromised, the product is held, tested and subsequently reworked, relabelled, and/or released or destroyed.

If food safety has not been compromised, the CCP-1C Authorized Person releases the product.

Where required, the CCP-1C Authorized Person provides retraining for the Facility Employee, who is responsible for weighing and batching the ingredients and/or for the CCP-1C Monitor.

CCP-1C Authorized Person determines the root cause of the deviation to assess whether preventive measures must be developed to prevent reoccurrence.

Once corrective actions have been completed, the CCP-1C Authorized Person evaluates the effectiveness of the actions taken, including preventative measures. If any deviations are identified, follows the deviation procedures as outlined above.

CCP-1C Authorized Person records any additional information concerning the deviation (including target dates for completion of corrective actions), corrective actions taken (including the results of the Food Safety Assessment and effectiveness checks), preventive measures (including target dates for completion), time(s) and date(s) completed and person(s) responsible on the CCP-1C Deviation Record. Signs and dates.

Once per Y time period, the CCP-1C Verifier observes the CCP-1C Monitor performing the monitoring function to ensure the SOP for Weighing and Mixing Products and the SOP CCP-1C Product Formulations and Recipes are being followed. Signs and dates the CCP-1C Monitoring Record, and records the time the verification was conducted. Records "observation" to indicate a check of the monitoring procedures was conducted.

Once per Y time period, the CCP-1C Verifier reviews X number of CCP-1C Monitoring Records and associated CCP-1C Deviation Records completed since the last verification for completeness and compliance. Signs and dates and records the time the verification was conducted.

Once per Y time period the CCP-1C Verifier reviews X number of CCP-1C Monitoring Records and compares the ingredients added to the mixer to the list of ingredients for that product as identified in the SOP CCP-1C Product Formulations and Recipes. Indicates on the CCP-1C Monitoring Record that the ingredient check was done by recording "Ingredient Check". Signs, dates and records the time the verification was conducted.

If deviations are found for any of the above procedures, the CCP-1C Verifier follows the Deviation Procedures for this CCP. Records the corrective actions, retraining (where required), preventive measures, date(s) and times completed and person(s) responsible on CCP-1C Deviation Record. Signs and dates.

CCP-1C Monitoring Record

CCP-1C Deviation Record

SOP for Weighing/ Mixing Products

SOP CCP-1C for Product Formulations and Recipes

Food Safety Assessment Procedures

Hold Procedures

11 Weighing/ Packaging/ Labelling/ Coding CCP-2C Presence of undeclared allergens (e.g., wheat, soy, eggs) in the finished product due to incorrect label application, use of incorrect packaging, use of incorrect list of ingredients and/or use of illegible list of ingredients on the label. Each package or container of product must have a correct label that is legible and that accurately reflects the ingredients in the product.

At X frequency, the CCP-2C Monitor checks the label in the packaging machine to ensure that the label (including ingredients listed) is legible and is an accurate reflection of the product being packaged.

Matches the label in the packaging machine to the master product label as per CCP-2C SOP for Label Check.

Compares the ingredients identified on the CCP-2C Monitoring Record to the label as per the CCP-2C SOP for Label Check.

CCP-2C Monitor attaches each product label to the back of the CCP-2C Monitoring Record and initials and dates. Signs and dates the CCP-2C Monitoring Record and indicates the time of the label check.

If the label in the packaging machine is incorrect or illegible and/or if the ingredients listed on the label in the packaging machine do not match the ingredients as listed in the CCP-2C SOP for Label Check and/or if the label on the product is not an accurate reflection of the product being packaged, the CCP-2C Monitor takes corrective actions as per CCP-2C SOP for Label Check and/or notifies the CCP-2C Authorized Person. Records the description of the deviation and corrective actions taken, including time completed on CCP-2C Monitoring Record. Signs and dates.

The CCP-2C Authorized Person places all affected product on hold as per Hold Procedures and makes an assessment as to whether food safety has been compromised as per written Food Safety Assessment Procedures. If food safety has been compromised the product is held, tested and subsequently released, reworked, relabelled or destroyed. If food safety has not been compromised the CCP-2C Authorized Person releases the product.

Where required, the CCP-2C Authorized Person provides retraining for the CCP-2C Monitor.

CCP-2C Authorized Person determines the root cause of the deviation to assess whether preventive measures must be developed to prevent reoccurrence.

Once corrective actions have been completed, the CCP-2C Authorized Person evaluates the effectiveness of the actions taken, including preventative measures. If any deviations are identified, follows the deviation procedures as outlined above.

CCP-2C Authorized Person records any additional information concerning the deviation (including target dates for completion of corrective actions), corrective actions taken (including the results of the Food Safety Assessment and effectiveness checks), preventive measures (including target dates for completion), time(s) and date(s) completed and person(s) responsible on the CCP-2C Deviation Record. Signs and dates.

Once per Y time period, the
CCP-2C Verifier observes the CCP-2C Monitor performing the monitoring function to ensure the CCP-2C SOP for Label Check is being followed. Signs and dates the CCP-2C Monitoring Record, and records the time the verification was conducted. Records "observation" to indicate a check of the monitoring procedures was conducted.

Once per Y time period, CCP-2C Verifier reviews "X" number of CCP-2C Monitoring Records and associated CCP-2C Deviation Records completed since the last verification for completeness and compliance. Signs and dates and records the time the verification was conducted

Once per Y time period the CCP-2C Verifier reviews X number of product labels found attached to the CCP-2C Monitoring Records to ensure that the ingredients identified on each of the labels continue to be an accurate reflection of the ingredients (and their components) used for that product. Compares the labels on the monitoring records to the master product labels found in the CCP-2C SOP for Label Check. Using the ingredient labels, compares the components of each of the ingredients (where applicable) to the product label for accuracy. Signs, dates and records the time the verification was conducted on the product label attached to the CCP-2C Monitoring Record to indicate the label was verified.

If deviations are found for any of the above procedures, the CCP-2C Verifier follows the Deviation Procedures for this CCP. Records the corrective actions, retraining (where required), preventive measures, date(s) and times completed and person(s) responsible on CCP-2C Deviation Record. Signs and dates.

CCP-2C SOP for Label Checks CCP-2C Monitoring Record Safety Assessment Procedures
Hold Procedures
12 Metal Detector CCP-3P

Presence of hazardous extraneous material (metallic) in alimentary paste due to failure of the metal detector to detect metal.

Presence of hazardous extraneous material (metallic) in alimentary paste due to failure of the metal detector to function as intended when metal is detected (i.e. line stops, alarm sounds, product is kicked off the line).

All product must go through a functioning metal detector.

Metal detector must detect each of the following metal wands during a test of the metal detector as described in the CCP-3P SOP for Metal Detector:
mm ferrous
mm non-ferrous
mm stainless

Metal detector must function normally when metal or metal wand is detected (Note: the manufacturer must define what "function normally" means for the metal detector at the facility (i.e., alarm must sound, conveyor must stop and product must be kicked off).

Facility employees are responsible for passing all product through a functioning metal detector as per the CCP-3P SOP for Metal Detector.

Once every Y time period, the CCP-3P Monitor observes the metal detector in use to ensure that all product is passing through the metal detector.

Once every Y time period, the CCP-3P Monitor, passes each of the following metal wands through the metal detector placing them on top of the product:
mm ferrous
mm non-ferrous
mm stainless
as per the CCP-3P SOP for Metal Detector. For each metal wand, the CCP-3P Monitor observes the metal detector to ensure the metal detector is detecting the metal wand and observes the functioning of the metal detector to ensure that when the metal wands pass through the metal detector, the appropriate alarms and/or line stoppage/product kick out occurs.

Records all findings and observations on the CCP-3P Monitoring Record and records the time the monitoring was completed. Signs and dates.

If all product is not passing through a functioning metal detector the CCP-3P Monitor notifies the CCP-3P Authorized Person.

For each of the metal wands indicated in the critical limits when tested:
If the metal detector is not detecting the metal wand, the metal wand is not working as intended, or if the metal detector is not functioning as intended (i.e., the appropriate alarms and/or line stoppage/product kick out does not occur) when each of the metal wands is passed through the metal detector, the CCP-3P Monitor repeats the test as per the CCP-3P SOP for Metal Detector. If the metal detector still does not detect the wand and/or does not function as intended, notifies the CCP-3P Authorized Person.

If the metal detector at any time indicates that metal is detected in the product (i.e., the appropriate alarms and/or line stoppage/ product kick out occurs), the Facility Employee stops the line and notifies the CCP-3P Monitor. The CCP-3P Monitor passes suspect product through the metal detector at least 2 more times to ensure that the metal detector is functioning normally. If the metal detector continues to identify metal in the product, notifies the CCP-3P Authorized Person. CCP-3P Monitor records all deviations and corrective actions, including the time completed on the CCP-3P Monitoring Record. Signs and dates.

If any of the above deviations occurs, the CCP-3P Authorized Person puts all affected product and/or product produced since the last good check on Hold as per Hold Procedures and makes an assessment as to whether food safety has been compromised as per written Food Safety Assessment procedures. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed. If food safety has not been compromised the CCP-3P Authorized Person releases the product. This may include notifying maintenance and/or the Outside Contractor to have the metal detector adjusted/recalibrated and/or the training or retraining of the CCP-3P Monitor.

CCP-3P Authorized Person determines the root cause of the deviation to assess whether preventive measures must be developed to prevent reoccurrence.

Once corrective actions have been completed, the CCP-3P Authorized Person evaluates the effectiveness of the actions taken, including preventative measures. If any deviations are identified, follows the deviation procedures as outlined above.

CCP-3P Authorized Person records any additional information concerning the deviation (including target dates for completion of corrective actions), corrective actions taken (including the results of the Food Safety Assessment and effectiveness checks), preventive measures (including target dates for completion), time(s) and date(s) completed and person(s) responsible on the CCP-3P Deviation Record. Signs and dates.

Once per Y time period, the CCP-3P Verifier observes the CCP-3P Monitor performing the monitoring function to ensure the CCP-3P SOP for Metal Detector is being followed. Signs and dates the CCP-3P Monitoring Record and records the time the verification was conducted. Records "observation" to indicate a check of the monitoring procedures was conducted.

Once per Y time period , the CCP-3P Verifier reviews X number of CCP-3P Monitoring Records and associated CCP-3P Deviation Records completed since the last verification for completeness and compliance. Signs and dates and records the time the verification was conducted.

If deviations are found for any of the above procedures, the CCP-3P Verifier follows the Deviation Procedures for this CCP. Records the corrective actions, retraining (where required), preventive measures, date(s) and time(s) completed and person(s) responsible on CCP-3P Deviation Record. Signs and dates.

CCP-3P Monitoring Record

CCP-3P Deviation Record

CCP-3P SOP for Metal Detector

Hold Procedures
Food Safety Assessment Procedures

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