SUBMITTED BY
MARIA TARIQ
20-ARID-2744
BS HND MORNING 3RD SEMESTER
SUBMITTED TO:
Miss Sowaba Muneer
Assignment No 1 (FOOD SAFETY)
HACCP
BAKERYIMPLEMENTATION ON
PRODUCTS (COOKIES)
HACCP (Hazard Analysis and Critical Control Points) is a globally recognized food safety
management system that helps food businesses and authorities to identify, evaluate and control
the hazards that are prone to cause significant risks to food safety.
HACCP is made of the following principles:
• Conduct a hazard analysis plan.
• Determine the critical control points.
• Set critical limits.
• Establish a monitor control system for CCP.
• Establishing corrective actions when monitoring recognizes that a particular CCP is not
under control.
• Establish procedures for verification to confirm the HACCP system is working effectively.
• Maintain a record concerning all procedures appropriate to principles and application.
Having a HACCP system in place is essential for all bakery businesses, which ensures that you
are complying with food safety laws and producing bakery items that are safe to consume.
Here are some specific considerations while applying HACCP in bakery products:
• All hazards must be considered during hazard analysis from initial stages with suppliers
and raw ingredients to processes and sale of the final product. Consider hazards from
each category of contamination, i.e., physical, chemical, microbial, and allergens, along
with their possible sources and effects on food. Also include hazards from cross-
contamination, personal hygiene, damaged machinery, and storage rooms.
• Your food safety system must have certain prerequisites in place before the
implementation of HACCP. This training includes the essentials of food safety, hygiene
practices, safe cooking, storage temperatures, waste disposal, and pest prevention.
• Some hazards are more significant than others that you are aiming to control with the
HACCP system. For example, a stage in the food production process where allergens
may contaminate other bakery products or a point where bakery machinery may leak oil
into the food.
• You must have a plan in place to deal with contaminated bakery products. The aim of
corrective action is to deal with problems immediately, make the product safe and
prevent potentially harmful products from being used and sold.
Product Description
• Product name and quantity:
Chocolate chip cookies (500g)
Slivered almond cookies (500g)
• Type of product:
Baked / Ready to eat.
• Possible allergens:
Chocolate chip cookie: wheat, egg, milk, and soy allergens
Slivered almond cookie: wheat, egg, milk, soya, and almond allergens
• Packaging method:
Plastic film packaging further in cardboard boxes
• Storage conditions:
Room temperature storage. Products are shipped at ambient temperatures in a clean truck.
• Shelf life:
Three months at room temperature
• Best before date:
The best before date is printed on the cardboard box as YY MM DD.
• Consumer details
General population. However, chocolate chip cookies are not suitable for people with egg, milk,
soy, or wheat allergies or gluten intolerance.
Slivered almond cookies are not suitable for people with egg, milk, nut, wheat allergies, and
gluten intolerance.
• Safety measures for the consumer:
Products that have passed the best before date can have quality defects.
• Location of sale:
Foodservice, retail, distributor, wholesale.
• Product label information:
Individual cookie box labels contain information such as product name, weight, ingredients,
allergens, nutritional table, claims, storage and handling instructions, best before date,
manufacturing company name, address, and contact information.
Corrugated box label contains information such as product name, best before date, the number
of cookie boxes, storage and handling instructions, manufacturing company name, address, and
contact information.
Raw Materials
• Ingredients:
• Wheat flour 7. Shell eggs
• Whole wheat flour 8. Butter
• Sugar 9. Skim milk powder
• Baking soda 10. Chocolate chips
• Vanilla flavor 11. Vegetable oil
• Molasses 12. Slivered almonds
• Food contact processing aid materials:
Baking spray
• Food contact packaging materials:
Clear polypropylene plastic films
• Nonfood contact packaging materials:
• Ink 5. Preprinted cardboard boxes
• Tape 6. Corrugated boxes
• Plain labels 7. Wooden pallets
• Shrinkwrap
• Chemicals (handwashing, sanitation, and maintenance)
• Hand soap 4. Sanitizer
• Hand sanitizer 5. Lubricant
• Degreaser
Process flow steps
• Receiving ingredients
• Weighing
• Mixing
• Wire cutting process
• Baking
• Cooling
• Packaging
• Storage
Hazard analysis plan
Hazards Type of hazards Causes
• Pathogen survival Biological Improper temperature
(Listeria distribution and
Monocytogenes, time/temperature applications
Escherichia Coli,
Shigella spp.,
Salmonella spp)
• Allergic reactions Chemical Presence of undeclared
allergies
• Presence of dangerous Physical Failure of metal detector to
extraneous metallic detect metals and reject the
material in the finished product when metal is
product. detected.
• Liquid Egg
• Organisms such Biological Improper use of temperature
as Salmonella during the storage.
and pathogens
• Dioxins and di- Chemical Through the exposure of
PCBs laying hens to chemicals at
the layer farm.
• Eggshells, metal
shavings, glass, Physical Poorly maintained facilities
wood, or plastic and equipment, packaging
from process materials, and poor safety
equipment materials.
• Wheat Flour
• E.coli and Improper packaging during
bacillus cereus Biological transportation. It will be
exposed to surrounding
contaminants.
• Insects and Physical Minor bugs cannot be seen
bugs clearly by workers.
• Skim Milk Powder
Biological Outbreaks from microbes are
• Bacterial generally caused by
species inadequate control of cooking
temperatures, cross-
contamination, slow rate of
cooling, and poor
refrigeration process.
• Migrants from Chemical Unregulated and uncontrolled
packaging use of chemical materials.
materials.
• Insects, hair, Physical Contaminated due to
plastics, metal, mishandling and poorly
and fabric maintained facilities and
equipment, packaging
material, and poor safety
practices.
• Butter
• Monocytogenes Biological Butter can contain several
and Aureus bacteria due to various
species ingredients used in
production. Or butter can be
spoiled after 10 days at room
temperature
• Aflatoxins,
Veterinary drug Chemical Unregulated and uncontrolled
residues, and use of chemical materials.
Disinfectants
• Metal, plastic, Physical Contaminated due to
glass, rubber, mishandling
wood parts, and
hair
• Chocolate Chips
• Staphylococcus Biological Present during the incoming
Aureus, of raw material and improper
Salmonella, handling and temperature.
Penicillium, and
Aspergillus
• Toxic Chemical Poisoning from ingestion of
contaminants high levels of Lead.
• Foreign Physical
materials Mishandled by workers
• Baking Soda
• Small stones Physical Mishandled by workers
• Sugar
• Pathogenic Biological Bacterial growth and toxin
bacteria formation due to lack of time
and temperature control.
• Over quantity of
sulfur dioxide,
dyes, and Chemical Fire and toxic gas leakage
chlorinated affect workers. Direct contact
organic b/w sugar and packaging
compounds paper can result in chemical
contamination of sugar
• Foreign
materials When a product is packed in
Physical a glass container
• Vanilla Extract
Cross-contamination with
• Allergens during Chemical other substances during
cross-contact in storage and production.
storage
• Foreign matter
Physical Small bugs are impossible to
see with the naked eye.
• Plastics Lack of handling and disposal
process
Monomers, solvents, Chemical
surfactants, plasticizers, Recycling of materials in
stabilizers, biocides, plastic production
flame retardants,
colorants Exposure to high temperature
• Box The boxes are stored in
Biological improper places that can risk
• Microorganisms contamination.
• Allergen Chemical Presence of allergen
products substances in the product.
• Foreign matter Physical Mishandling by workers
• Receiving
Biological Temperature abuse and
• Microbes unhygienic handling
• Low grade flour Chemical Inappropriate level of
and skim milk moisture and protein flour
and milk powder.
• Foriegn matter
like cotton Physical
thread, broken Container bag, inappropriate
pieces of sticks, storage
stones
• Weighing
Biological Temperature abuse
• Microbes
• Metal fragments Physical Metal clips and parts from
multi-head weighing
machines and conveyors may
stick to the product.
• Mixing
• Chlorella, Biological Insects like flies, ants and
Salmonella rodents
• Lubricant and Chemical Rust because of lack of good
cleansing agent maintenance
• Screw and metal
pieces Physical Contamination of foriegn
matter
• Wire cutting
• Lubricant Chemical Lack of maintenance
• Metal Physical Metal fragments scratched
fragment/dust from sizing machinery may
stick to the product.
• Baking
• Microbes Biological Pathogen survival due to
mismanaged temperature
distribution and time
applications
• Cooling
Pathogen growth due to
• Microbes Biological temperature abuse and
duration of the cooking
process.
• Foreign matter Physical Improper handling
• Packaging
• Pathogens Biological Due to leakage of package
• Foriegn matter Physical Improper personal hygiene.
Low graded cartons and
improper packaging.
• Storage
Presence of insects and
• Bacterial Biological rodents
microbes
• Dust Physical Holding goods during pallets
accumulation and incorrect rules for
stacking.
Critical control points
Critical control points Critical limits Monitoring procedures
• Baking The internal temperature of • Measure the product
the product should be at least internal temperatures
85 degrees celsius for a from different areas of
minimum of 1 minute. the oven (top, middle
bottom) during each
baking session.
• Insert the
thermometer in the
center of product and
wait until thermometer
reading is steady.
• Record each result on
the “daily baking
record” including date,
time, and initials.
2. Metal detecting The metal detector must • Test the metal
detect 2mm ferrous, 3mm detector at start, every
nonferrous, and 3.5mm hour during
stainless steel test samples packaging, and at the
when the samples are end of packaging run.
passed through the detector
with product. The metal • Check the metal
detector must reject the detector by passing a
product. sample of metal
through the detector
to ensure it is
operating safely and
effectively.
• Check metal samples
of given dimensions
each check must
include three sample
tests.
• Insert the metal
sample into the
product and pass
product package
through a metal
detector.
• Every time a metal
contaminant is
detected the metal
detector belt must
retract and rejected
product must drop into
the rejection box.
• Record the metal
sample check as
acceptable or
nonacceptable on the
“daily metal detector
check record.”
3. Retail box packaging and The final product must be • Daily check the
labeling packaged in a box that has product packaging
the correct allergen material at the start,
information on it. middle, and end of the
The product label is printed process.
on packaging material.
• At the start of the
process make sure
there are no product
packaging processes
present in the area.
• Check product
packaging material to
confirm the accuracy
of packaging material.
• Ensure all the
information is
correctly displayed.
• Ensure leftover
packaging material is
disposed of from the
packaging area.
• Compare the
packaging material to
master packaging
material.
• Record this packaging
check on “daily
packaging record”
• Daily baking record
Date Time Batch Product Product Initials
number name internal
temperature
(degree
Celsius)
Top Middle Bottom
2015/11/02 12:00 1 Cookie 87 87 86 CC
2015/11/02 13:04 2 Cookie 86 88 82 CC
2015/11/02 16:00 3 Cookie 87 89 85 CC
• Daily metal detector check record
Date Time Batch Product 2mm 3mm 3.5mm initials
number number ferrous nonferro stainless
us steel
2015/11/02 12:00 1 Cookie Present Present Present SM
(start)
13:05 1 Cookie Present Present Present SM
14:07 1 Cookie - Present Present SM
15:37 1 Cookie Present Present Present SM
16:04 1 Cookie Present Present Present SM
17:05 1 Cookie Present Present Present SM
17:44 1 Cookie Present Present Present SM
(finish)
• Daily packaging record
Date Product batch# # of Packaging Initials
cases material
check
Start Middle End At new lot
of
packaging
materials
2015/1/02 Cookie 1 19 Yes Yes Yes Yes CL
Cookie 2 44 Yes Yes Yes Yes CL
Cookie 3 26 Yes Yes Yes Yes CL
Cookie 4 28 Yes Yes Yes Yes CL
Corrective Actions
• Baking
Establishing corrective actions Establishing verification procedures
When critical limits are not fulfilled for one or • At the end of each day review “Daily
more samples Baking Record” to ensure it has been
completed.
• The product should be baked for a
longer period of time until product’s • Once per week temperature check
internal temperature reaches 85 follows written monitoring procedure.
degrees celsius or the product must • If nonconformance is found during the
be destroyed. verification procedure, investigate the
cause and take necessary actions.
• Investigate the cause of
nonconformance and take corrective • Record all the observations
actions to prevent reoccurrence.
• Record all the nonconformances and
corrective actions in “Daily Baking
Record.”
• Metal detection
Corrective actions Verification procedures
• When metal detector fails to detect: • At the end of each day review the
“Daily Metal Detector Check Record”
• Immediately stop the line and to ensure it has been properly
place all the products checked.
processed since the last
successful check on hold. • Once per week ensure monitoring of
metal detector follows written
• All products in processed monitoring procedure.
stage while the metal detector
was not operative should be • If nonconformance is found during the
held until they are passed verification procedure investigate the
through a functional metal cause and take action accordingly.
detector.
• Record all the observations.
• When a product is rejected by metal
detector
• Inspect the product for the
metal piece
Investigate the cause of nonconformances to
prevent reoccurrence. Record all the
corrective actions.
• Retail packaging and labelling
Corrective actions Verification procedures
• Previous product packaging materials • Review the “Daily Packaging Record”.
present in the packaging area.
• Once per week ensure that it has
• Immediately place the been properly completed and follows
packaging on hold. written monitoring procedure.
• Remove previous product • If nonconformance is found, take
packaging materials. necessary corrective actions.
• Inspect the area and ensure • Record all the packaging.
corrective actions.
• Incorrect packaging material.
• Immediately stop the line and
place the packaged products
on hold.
• Products on hold must be
repackaged with correct
packaging materials or if a
critical limit is not met, the
product must be destroyed.
So HACCP helps businesses to:
• Adapt methods to prevention and detection to their application.
• Allowing them the ability to implement new strategies and technologies more easily.
By applying HACCP the bakery can ensure high quality to reduce the risk of hazards. The
implementation of HACCP boosts customers' trust.
