Developing a HACCP Plan for Various Products
Hello! I am working on creating a food safety plan for a warehouse that receives bulk sugars, teas, and spices and repackages them/creates seasoning blends. Can I incorporate all ingredients as one or do I need a different hazard analysis for each different product (i.e. one for teas, one for spices, etc.)? I understand that you can group like products together but I am somewhat confused since products may go through different processes. For example, the teas will be repackaged, while some spices will be used in a mixer to create a blend.
If it's a different process, it needs a separate hazard analysis.
Marshall
Hello! I am working on creating a food safety plan for a warehouse that receives bulk sugars, teas, and spices and repackages them/creates seasoning blends. Can I incorporate all ingredients as one or do I need a different hazard analysis for each different product (i.e. one for teas, one for spices, etc.)? I understand that you can group like products together but I am somewhat confused since products may go through different processes. For example, the teas will be repackaged, while some spices will be used in a mixer to create a blend.
As MGourley said, different processes require different HACCP plans.
However, if these items go through enough similar steps, it's possible to see that as one HACCP plan. We technically have repacking under the same HACCP Plan as our liquid blending HACCP Plan, because they both go through the same sort of process. We also have similar dry processes as you describe in our facility too, and I have it all listed under one HACCP plan since there are commonalities with processes and similar equipment being used.
If you're doing these products on different lines that follow completely different flows, then I would suggest different HACCP plans. I just tend to try to combine what I can if the flows are similar. We once had 9 HACCP plans and we're down to 4. We have a ton of branching elements, but the processes are fairly easy to follow. Our auditors have been fine with our HACCP plans since I made the changes 2 years ago.
It also depends on how you want to set it up. I've also seen in another place on the forum that a lot of people prefer to keep the elements as simple as possible without branching, so that will create more HACCP plans. However, if you're in an auditing scheme like BRC, the number of HACCP plans you have directly relates to the length of your audit. :headhurts:
QAGB
As MGourley said, different processes require different HACCP plans.
However, if these items go through enough similar steps, it's possible to see that as one HACCP plan. We technically have repacking under the same HACCP Plan as our liquid blending HACCP Plan, because they both go through the same sort of process. We also have similar dry processes as you describe in our facility too, and I have it all listed under one HACCP plan since there are commonalities with processes and similar equipment being used.
If you're doing these products on different lines that follow completely different flows, then I would suggest different HACCP plans. I just tend to try to combine what I can if the flows are similar. We once had 9 HACCP plans and we're down to 4. We have a ton of branching elements, but the processes are fairly easy to follow. Our auditors have been fine with our HACCP plans since I made the changes 2 years ago.
It also depends on how you want to set it up. I've also seen in another place on the forum that a lot of people prefer to keep the elements as simple as possible without branching, so that will create more HACCP plans. However, if you're in an auditing scheme like BRC, the number of HACCP plans you have directly relates to the length of your audit. :headhurts:
QAGB
Oops! I meant I agreed with MGourley that different processes need different hazard analyses.
What I meant to add to that was there should be one hazard analysis per HACCP Plan. However, you may be able to combine those items into one HACCP Plan if the flows are similar enough. If you can do that, then you should be able to have one hazard analysis.
I got very wordy without actually explaining the integral part.
QAGB
Your ingredients are your raw materials. They could all be placed under the same Raw Material Risk Analysis. However, if others have pointed out, significant differences in the processing means your Processing Risk Analysis should show different sets of contamination control. However, I believe you could incorporate all of the Risk Analyses into one HACCP plan which becomes the basis for your food safety program.