5 replies to this topic

[Buddha321]

We are dry blending company. I received an NC for not having "waste" in my HACCP Flow Chart.  If you list waste - can you tell me exactly what that is referring to? Yield loss? When I think of waste, I think of trash. 

[Scampi]

Waste is material that needs to be disposed of--and included not only the actual product but packaging as well 

You should have waste coming from different parts of your process and shown on your flow chart 

 

You never sweep up spills or overflowed product???

 

HACCP 101---ALL process involved in production that could become a source of contamination need to be addressed

 

 

Yield loss should be explained in your recall program however, if you know you lose, say 3% of you volume/day due to yield loss, you'll never be able to "find" all 100% of your inputs--so an explanation is required

[Buddha321]

Thank you! That explains it. 

[Tony-C]

Hi Buddha321,

 

This requirement comes from The SQF Food Safety Code: Food Manufacturing – System Elements clause 2.4.3.6 The food safety team shall develop and document a flow diagram covering the scope of each food safety plan. The flow diagram shall include every step in the process, all raw materials, packaging, service inputs (e.g., water, steam, gasses as applicable), scheduled process delays, and all process outputs including waste and rework. Each flow diagram shall be confirmed by the food safety team to cover all stages and hours of operation.

 

Here is an example of a flow diagram showing waste out of the flow in steps 16 and 22.

 

 BRCGS Flow Diagram Example.jpg   93.83KB   1 downloads

 

You could also include waste packaging, for example when you de-box ingredients there is waste packaging.

 

Kind regards,

Tony

[TylerJones]

Hi Tony,

 

Shouldn't there be a reject, rework or trash optional output for step 24 Metal Detection? Where happens is metal is detected in this flow?

 

Thanks,

 

Tyler 

[Tony-C]

Hi Tony,

 

Shouldn't there be a reject, rework or trash optional output for step 24 Metal Detection? Where happens is metal is detected in this flow?

 

Thanks,

 

Tyler 

 

Hi Tyler,

 

The flow diagram example I posted is from BRCGS Guidance. I can understand your thinking, they might say rejection is not a natural part of the process. Also, you might get rejected ingredients or products many stages in the process, for example an ingredient rejected for being out of spec. on delivery. Are you going to put that in your process?

 

At least you are not likely to get a non-conformance from BRCGS if you omitted it 

 

Kind regards,

 

Tony