I have been viewing this form for a while now and got several ideas on how to get my Food Safety Plan/HACCP Plan in order, however this is my first time posting. I also wasn't sure whether to post this in HACCP or FSMA.
I currently am struggling in figuring out how to organize my Food Safety/HACCP Plan and I was hoping someone would be able to give me some insight.
We are a bakery manufacturer that makes over 80 SKU's, majority of them are frozen, unbaked different types of dough that are cut into a variety of shapes and sizes and filled with a variety of different fillings. As discussed on this forum several times, I am trying to group my products together so that I don't have too many Flow Charts, Hazard Analysis, etc...
Some of the products I make are as follows:
Non Filled, Frozen, Puff Pastry Dough (has both Non Dairy and Dairy Recipes) (Variety of shapes and sizes)
Non Filled, Frozen, Danish Dough (Contains Yeast, Eggs, and has both Non Dairy and Dairy Recipes) (Variety of shapes and sizes)
Non Filled, Frozen, Croissant Dough (Contains Yeast, and has both Non Dairy and Dairy Recipes) (Variety of shapes and sizes)
Filled, Frozen Puff Pastry Products (Uses Puff Pastry Dough + variety of different shapes, sizes, fillings and allergens being used) (Some fillings are used directly from vendor, some are being mixed in house)
Filled, Frozen Danish Dough Products (Uses Danish Dough + variety of different shapes, sizes, fillings and allergens being used) (Some fillings are used directly from vendor, some are being mixed in house)
Baked, Frozen Danish Products (Uses Danish Dough + variety of different shapes, sizes, fillings and allergens being used) (Some fillings are used directly from vendor, some are being mixed in house)
Baked Cookies (Contains Eggs, does not contain dairy(milk)) - Variety of different fillings.
Generally all these products have a very similar process with the exception of filling and baking which only some products have.
I grouped my products as follows;
1) Production Non-Filling
2) Production Filling
3) Baked Goods
My questions are as follows:
1) Does the way I grouped my products make sense? My only concern is that the each of these product groups has a lot of different ingredients associated with them and while some products in a group contain Dairy others do not.
If the way I grouped my products is OK:
1) Does my Flow Diagram make sense? Is there any adjustments you might make? I know some people discussed numbering the boxes on this forum. That is something I was considering doing once completing the flow diagram.
2) Can I go a step further and combine Production Non-Filling and Production Filling or should these be separated since we are mixing our own fillings for some of our products?
3) Do I need to make a Ingredient Hazard Analysis and Process Hazard Analysis for each Product Category? This would be redundant as the ingredients I am using are in all three product categories.
My idea instead if it makes sense was to make One Ingredient Hazard Analysis for all incoming Ingredients into the factory.
In regards to the Process Hazard Analysis (as you can see by the flow chart), most of the processes are the same for all product categories with the exception of filling and baking. Can I make one Process Hazard Analysis and just list the Mixing Filling Step, Fill Step and Bake Step as separate rows in the Process Hazard Analysis?
Hopefully this made sense and any insight you can give would be greatly appreciated!
Thank You!
Edited by CapAce, 27 March 2019 - 01:34 AM.