One HACCP plan for 5 different production lines.......
Hello,
In order to minimize the volume of work I am about to embark on, I would like to attempt to combine different products into one HACCP plan. The products include; frozen uncooked cookies, frozen uncooked pastries, frozen uncooked bread rolls, frozen (baked) cakes, as well as a dry mix preparation line.
Maybe I am being unrealistic in trying to shoehorn all of this into one plan but I would like to understand any of your experience in handling this type of situation and the resultant problems encountered if this is done.
Any help will be greatly appreciated.
Thanks,
I don't claim to be an expert on this but I could see the frozen uncooked cookies, pastries and bread all having one plan, because their process is going to be fairly similar... along the lines of chuck all the ingredients in a bowl, mix and form into the required shapes, then freeze and pack. you could possibly even put the dry mix prep into this category.... the baked ones though have a different process due to the baking so I can imagine that needing a seperate haccp. Even so, 2 is better than 5.
Thanks Kehlan, appreciate the response. I was also thinking that the cooking element constitutes different processing to the uncooked lines therefore requires a second HACCP plan. This falls in line with 9 CFR 417.2 which states that "a single HACCP plan may encompass multiple products within a single processing category".
With this in mind, does anyone else know of any regulations that relate specifically to what a single HACCP plan can and cannot include?
I don't claim to be an expert on this but I could see the frozen uncooked cookies, pastries and bread all having one plan, because their process is going to be fairly similar... along the lines of chuck all the ingredients in a bowl, mix and form into the required shapes, then freeze and pack. you could possibly even put the dry mix prep into this category.... the baked ones though have a different process due to the baking so I can imagine that needing a seperate haccp. Even so, 2 is better than 5.
Thanks Kehlan, appreciate the response. I was also thinking that the cooking element constitutes different processing to the uncooked lines therefore requires a second HACCP plan. This falls in line with 9 CFR 417.2 which states that "a single HACCP plan may encompass multiple products within a single processing category".
With this in mind, does anyone else know of any regulations that relate specifically to what a single HACCP plan can and cannot include?
Hi Letmeinnow,
I agree with Kehlan. You most likely would be better off with two separate HACCP plans. However, if your processes are similar enough that they follow mostly the same common steps, you could technically have one HACCP plan. You have to show all justification for it though.
Perhaps, both of the frozen (baked or unbaked) products share the following steps (just a general flow such as one provided by Kehlan):
- Ingredient Dumping
- Blending
- Forming
- Freezing
- Metal Detection
- Pack
However, between the baked and unbaked frozen products, your basic flow could look like this (with one additional step between baked and unbaked [cooking step]):
Baked
- Ingredient Dumping
- Blending
- Forming
- Cooking
- Freezing
- Metal Detection
- Pack
Unbaked
- Ingredient Dumping
- Blending
- Forming
- Freezing
- Metal Detection
- Pack
You can even combine the dry prep into the same HACCP plan, pending it has the same or similar common steps (ingredient dumping, blending, metal detection, pack). You just have to sort of work out the diagram to ensure the flows work out for each product type in the common process. I've created a very rudimentary flow diagram that could work for all three product types, if the flows are similar to what is described. Perhaps it's something to get you started.
QAGB
Gen Flow Diagram.pdf 80.57KB 135 downloads
Hi Letmeinnow
Yes it is possible to one one HACCP plan for several production lines. In your case you can combine four production lines (frozen uncooked cookies, frozen uncooked pastries, frozen uncooked bread rolls, frozen (baked) cakes,) into one HACCP plan and have the second HACCP plan for dry mix production line.
This will not only reduce your work but should also reduce Audit time so thus cost.
Kind regards
Humaid Khan
MD
Halal International Services
Hi LMIN,
And see this very recent thread -
http://www.ifsqn.com...r-each-product/
And if you would like to see a lot more discussions around this topic, try searching for "foodservice".
Thank you all for your responses.