We have a procedure in which we analyse our incoming ingredients for certain parameters (CCP1). If it is below a certain levels we can release it. We know that in our processing we can reduce this parameter until below desired limit (no legal limits apply, only industry limits).
We have recently found that the quality and availability of our ingredients is decreasing. Causing us to needing to accept ingredients which are above the parameters of our incoming ingredient CCP.
I have talked to our directors and agreed to release the ingredient for processing only if we analyse the end-product and verify that it is in spec. This might still result in a downgrade if it is not in spec, but hopefully we can at least release some of this product which is in spec into the market.
However, this product still failed our CCP for incoming limits. My QA heart is not happy with releasing product that failed it's CCP.
So I am now looking to re-define our process to allow a second control measure if the first CCP fails.
But I am not sure how to put that into our HACCP plan.
Making a final ingredient analysis a mandatory CCP is not an option because the analysis for this parameters can take days. And our product and supply chain cannot handle that on a regular basis.
Does any of you have any brilliant suggestions?