Switch to two HACCP plans, or stay with one?

We are a coffee roaster, and we also do instant coffee packing.  We have always had one HACCP plan, which included both fresh coffee and instant coffee.  Instant coffee has never been part of our SQF audit because none of our customers requiring SQF purchase instant coffee, though we obviously still included it in our HACCP plan.  We are adding tea, which again has no SQF customers.  

Would you split up tea and instant coffee away from fresh coffee, or put all three on the same HACCP plan?

Tea and Instant Coffee have exactly the same process, being run on the exact same machines etc. (Open bulk bag, dump in hopper, pack through machine)

Fresh Beans come in green and we roast and grind and flavor and do other processing steps to, none of which are performed for tea or instant coffee.  

Tea and Instant Coffee are packed in a sectioned off room, with dedicated machines (fresh coffee is never in this room) way in the back of our facility.  

Would adding a second HACCP plan cause any problems with our scheduled audit for one HACCP plan?  Again no customer requires SQF when it comes to the proposed new HACCP plan.  

We are a coffee roaster, and we also do instant coffee packing.  We have always had one HACCP plan, which included both fresh coffee and instant coffee.  Instant coffee has never been part of our SQF audit because none of our customers requiring SQF purchase instant coffee, though we obviously still included it in our HACCP plan.  We are adding tea, which again has no SQF customers.  

 

Would you split up tea and instant coffee away from fresh coffee, or put all three on the same HACCP plan?

 

Tea and Instant Coffee have exactly the same process, being run on the exact same machines etc. (Open bulk bag, dump in hopper, pack through machine)

Fresh Beans come in green and we roast and grind and flavor and do other processing steps to, none of which are performed for tea or instant coffee.  

 

Tea and Instant Coffee are packed in a sectioned off room, with dedicated machines (fresh coffee is never in this room) way in the back of our facility.  

 

Would adding a second HACCP plan cause any problems with our scheduled audit for one HACCP plan?  Again no customer requires SQF when it comes to the proposed new HACCP plan.  

Do they have the same hazards ?

IIRC ochratoxin A is specific to coffee ?

Very similar hazards, and in US there is no actual criteria right now other than recognition/awareness of ochratoxin (according to my last couple auditors).  I have aW records and some literature stating its not an issue if dry enough.  I address this during receiving of materials, which I have split up between "Receiving Tea" and "Receiving Instant Coffee", and individual hazards are addressed to each.  Fresh roasted coffee has more and differing hazards than instant.   

The point is that different hazards tend to > different haccp plans.

I would say you will need to have two HACCP plans. One for coffee ( which you have currently) including fresh and instant in the same plan. And one for Tea as the process steps are different. I am assuming you are roasting coffee and blending teas without a thermal process correct? I worked with a Coffee Roast in the US whom had similar processes. They roast coffee and also produced coffee pods along with blended tea for wholesale and I developed two HACCP plans for them. They had no issues with their SQF audit.

The instant and the tea have the exact same steps, roasted coffee is totally different.  Instant and Tea is simply opened from a bulk container, and re-packaged.    Fresh roasted coffee is roasted here.  Tea is only black tea, single supplier, non blended, dust.  

Auditors often charge one price for 1-3 HACCP plans, then higher for, say, 4-6.

It still sounds like you will have 2 HACCP plans.

Thank you guys!