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HACCP Plan 2.4.3.1

SQF HACCP HELP 2.4.3.1

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#1 Loni Banaszak

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Posted 19 May 2015 - 06:46 PM

Hi Guys,

 

Since I trust all of your guys judgment, and you all have been so helpful to me, I need a favor. Before I get any further in my HACCP Plan, Can some take a look at it and tell me if I am heading in the right direction?

 

We received a finding at our desk Audit that basically said "your HACCP plan sucks", So either I found this template online or someone offered it in here I can t remember. But I have been filling it out with the things we do here at Rez-Tech (Plastic Jars Mfg)

 

I am hoping this is the right direction because I've already spent two days on it.

 

TIA

 

Loni

 

PS if someone offered this on here is it ok that I am using your template?

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Thanks,

 

Loni


#2 Simon

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Posted 19 May 2015 - 07:36 PM

It looks like the HACCP plan I made about a dozen year's ago; it was state of the art at the time. :smile:

Things have moved on since then with other potential hazards such as allergens and defects critical to consumer safety to consider.

That said it still forms a good basis, so I'm not sure it totally sucks.

 

Was your desk auditor more specific on how and why it sucks or is he/she a complete jerk?

 

I'm not precious about my work...can you tell. :lol:


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#3 Charles.C

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Posted 19 May 2015 - 10:23 PM

Hi Loni,

 

As I understood, yr immediate woes were related primarily to Prerequisites as noted here -

 

http://www.ifsqn.com...412/#entry89137

 

I deduce there may be a few more to come.  Sorry about that but repeated headaches are IMEX  the norm. during the first run. No need to worry too much, just a question of time and perseverance.

 

In addition to Simon's query over details of comments on the HACCP plan itself  you might also consider posting a list of yr proposed Prerequisite programs to enable users of the SQF Code to comment on that also.


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Charles.C


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#4 Loni Banaszak

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Posted 21 May 2015 - 01:47 PM

It looks like the HACCP plan I made about a dozen year's ago; it was state of the art at the time. :smile:

Things have moved on since then with other potential hazards such as allergens and defects critical to consumer safety to consider.

That said it still forms a good basis, so I'm not sure it totally sucks.

 

Was your desk auditor more specific on how and why it sucks or is he/she a complete jerk?

 

I'm not precious about my work...can you tell. :lol:

Hi Simon,

 

She said our

 

plan was developed but the methodology is not referenced

the flow diagram was too general

the hazard analysis does not include the review of biological and chemicals

the ccp summary is not properly documented and does not document actual hazards, critical limits monitoring activities verification and corrective action

 

(Note: those were the findings on the HACCP plan I did not attach to this post. The one attached to the post is the new one I am working on)


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Thanks,

 

Loni


#5 Loni Banaszak

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Posted 21 May 2015 - 01:49 PM

Hi Loni,

 

As I understood, yr immediate woes were related primarily to Prerequisites as noted here -

 

http://www.ifsqn.com...412/#entry89137

 

I deduce there may be a few more to come.  Sorry about that but repeated headaches are IMEX  the norm. during the first run. No need to worry too much, just a question of time and perseverance.

 

In addition to Simon's query over details of comments on the HACCP plan itself  you might also consider posting a list of yr proposed Prerequisite programs to enable users of the SQF Code to comment on that also.

 

Hi Charles,

 

 

Thank you, the one attached is in process, I was planning on listing out all our pre reqs on the last page. I am more worried that I am actually doing this right. I have no one here at my company whom is familiar with HACCP at all. I took a class last year but it was WAY over my head.

 

I am sorry if I post too many questions, Its just that you guys are so smart and have been so helpful to me.

 

 


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Thanks,

 

Loni


#6 Simon

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Posted 21 May 2015 - 01:54 PM

Ok Loni, feel free to post the finished HACCP for review and if you have specific question just ask.

What hazards does SQF say you should consider in your hazard analysis?

Also in your old plan what CCP’s did you identify if any?

Regards,
Simon


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#7 Loni Banaszak

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Posted 21 May 2015 - 02:06 PM

Ok Loni, feel free to post the finished HACCP for review and if you have specific question just ask.

What hazards does SQF say you should consider in your hazard analysis?

Also in your old plan what CCP’s did you identify if any?

Regards,
Simon

 

SQF stated possible hazards at a minimum are Microbiological, Chemical, Physical, at our discretion we may separate out allergens, microbial contamination, microbial growth, radiological hazards, metal, glass etc.

 

In the original plan there were no CCPs actually identified, only Employee Safety concerns (burns, cuts etc.), which we have processes in place to eliminate. Thanks I will post the finished version here later today. I am hoping to get it finished today.

 

Thanks for all the info :)


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Thanks,

 

Loni


#8 RG3

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Posted 22 May 2015 - 12:07 AM

Hi Loni,

 

   On your flow diagram you can expand more on manufacturing. I'm not sure how many different machines you may use or how many different tasks the machine does but at each step it may pose a different risk. By just saying manufacturing it may be to vague. The flow chart is perfect to send to a customer, but not for an actual hazard analysis.

   What I see you using is something I understand to be more of a Food Safety Risk Analysis Matrix which is more geared to how you justified what is a CCP in your HACCP Plan. IMEX I see something separate to this breaking down each Hazard at each step of your process. For example:

 

Raw Material Receipt

   Hazards

  • Biological - None Identified
  • Physical - Possible Foreign Material (metal, wood, plastic)
  • Chemical - Packaging material not acceptable for intended use

Then for each of these you would need to ask..

 

Are any potential Food Safety Hazards Significant

  • Biological - NO
  • Physical - NO
  • Chemical - NO

then your Justification For Decision

  • Biological - N/A
  • Physical - Trailer is inspected at time of receipt. Lack of history with recalls or injury.
  • Chemical - Hazard not expected  due to lack of incidence (recall). We have a Vendor Approval Process with Letter of Guarantees.

What Control Measures can be applied to prevent significant hazards?

 

Is this Step a CCP?

 

And do this for every step of your flow diagram.

 

P.S.

How can you have a Critical Limits, Monitoring and Corrective Actions without any CCP's?


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#9 Simon

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Posted 22 May 2015 - 06:01 AM

P.S.

How can you have a Critical Limits, Monitoring and Corrective Actions without any CCP's?

 

I agree with this. And the point that if different products and processes (with different / specific hazards) are in manufacturing then it should be broken down further.

 

RG3's ideas for a HACCP plan are much more up to date and comprehensive, but one thing to bear in mind this is packaging and not food and it can be simpler as long as it is comprehensive enough. :smile:

 

Regards,

Simon 


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#10 Philips

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Posted 27 May 2015 - 08:19 AM

Hi,

 

Your process flow diagram does not meet the ISO 22000 Standard requirements....., the requirements is explicit on clause 7. 3.5.1 that the process flow diagram must show the sequence and interactions of all steps, where raw materials, ingredients and intermidiate products enter the flow (for your process frow where is the masterbatch entering the process)? where reworking and recycling take place (for your process flow, where is re-cycled material re-enters the process)? and where end producs, intermeditate and waste are released or removed (for your process, where does waste get released from the processes)? You need to demonstrate all these inclduing how does the packagin material come in the process and atb whatv process step.

 

Regards


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#11 Charles.C

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Posted 27 May 2015 - 10:23 AM

Hi,

 

Your process flow diagram does not meet the ISO 22000 Standard requirements....., the requirements is explicit on clause 7. 3.5.1 that the process flow diagram must show the sequence and interactions of all steps, where raw materials, ingredients and intermidiate products enter the flow (for your process frow where is the masterbatch entering the process)? where reworking and recycling take place (for your process flow, where is re-cycled material re-enters the process)? and where end producs, intermeditate and waste are released or removed (for your process, where does waste get released from the processes)? You need to demonstrate all these inclduing how does the packagin material come in the process and atb whatv process step.

 

Regards

 

Thanks for yr comments.

 

But please note that the haccp plan is for SQF packaging.


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Charles.C


#12 Loni Banaszak

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Posted 27 May 2015 - 01:03 PM

Hi,

 

Your process flow diagram does not meet the ISO 22000 Standard requirements....., the requirements is explicit on clause 7. 3.5.1 that the process flow diagram must show the sequence and interactions of all steps, where raw materials, ingredients and intermidiate products enter the flow (for your process frow where is the masterbatch entering the process)? where reworking and recycling take place (for your process flow, where is re-cycled material re-enters the process)? and where end producs, intermeditate and waste are released or removed (for your process, where does waste get released from the processes)? You need to demonstrate all these inclduing how does the packagin material come in the process and atb whatv process step.

 

Regards

 

Thank you Phillips, But I am trying to get SQF certified, From what I have read in the standard I believe it meets the requirements. Thank you for the input. It is greatly appreciated.


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Thanks,

 

Loni


#13 Loni Banaszak

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Posted 27 May 2015 - 01:05 PM

Hi Loni,

 

   On your flow diagram you can expand more on manufacturing. I'm not sure how many different machines you may use or how many different tasks the machine does but at each step it may pose a different risk. By just saying manufacturing it may be to vague. The flow chart is perfect to send to a customer, but not for an actual hazard analysis.

   What I see you using is something I understand to be more of a Food Safety Risk Analysis Matrix which is more geared to how you justified what is a CCP in your HACCP Plan. IMEX I see something separate to this breaking down each Hazard at each step of your process. For example:

 

Raw Material Receipt

   Hazards

  • Biological - None Identified
  • Physical - Possible Foreign Material (metal, wood, plastic)
  • Chemical - Packaging material not acceptable for intended use

Then for each of these you would need to ask..

 

Are any potential Food Safety Hazards Significant

  • Biological - NO
  • Physical - NO
  • Chemical - NO

then your Justification For Decision

  • Biological - N/A
  • Physical - Trailer is inspected at time of receipt. Lack of history with recalls or injury.
  • Chemical - Hazard not expected  due to lack of incidence (recall). We have a Vendor Approval Process with Letter of Guarantees.

What Control Measures can be applied to prevent significant hazards?

 

Is this Step a CCP?

 

And do this for every step of your flow diagram.

 

P.S.

How can you have a Critical Limits, Monitoring and Corrective Actions without any CCP's?

For your PS: I put CCPs in place for things that I thought were CCPS, but after discussion with our auditor these were things that are more geared towrd our safety plan. With the new HACCP plan I have been working on its looking we have no CCPS.

 

Fingers crossed this is true and it gets accepted.

 

I will however expand on my manufacturing section as you suggested.

 

Thank you for the tip! Its greatly appreciated.


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Thanks,

 

Loni






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