HACCP PLAN

Organization has conducted and documented a HACCP plan, when HACCP system established. Organization has established documented procedures to ensure consistency and compliance with the requirements of HACCP standard and the organizations stated food safety policy. The procedures have made provisions to ensure that the organization receives relevant information on the conditions relating to food safety, including regulatory requirements.

GENERAL
The organization has developed a HACCP plan, which specified: Relevant hazards, biological, chemical or physical; Where the relevant hazards have controlled (Critical control points (CCP)); The critical limits observed for selected critical control points; The monitoring method used; The measures taken those monitoring methods indicate a critical limit is out of control; Responsibility and authorities for monitoring / controlling each control point

Supporting Documents: Annexure- A7

PRODUCT DESCRIPTION
The product description includes relevant safety information such as composition, physical / chemical structure, packing and storage. The description of the end use is based on the expected use of the product by the consumers. Different raw material, ingredients and packing materials help in defining the Product. A list for better understanding on above basis of the products is given.

Supporting Documents: Annexure A1 & A3

IDENTIFICATION OF THE INTENDED USE OF THE PRODUCT

Potential users and consumers have identified for product. The intended uses with regard to storage, preparation, where appropriate, and serving has described.

Supporting Documents: Annexure- A2

PROCESS DESCRIPTION
The team carefully studied all process stages and prepared process flow diagram. The team has also conducted on-site verification of the flow diagrams.

The process flow diagrams of different products indicating all stages and conditions for each product are covered, and are given in HACCP Plan.

Supporting Documents: Annexure- A4 IDENTIFICATION OF HAZARDS

All potential hazards likely to occur has identified, recorded and evaluated according to their severity and likelihood of occurrence. This evaluation has documented. On the basis of the evaluation, the relevant hazards, which require control, are identified with regard to the stated food safety policy. The identification has based on the conditions described in the standard.

Supporting Documents: Annexure- A5

ESTABLISHMENT OF CONTROL MEASURES

After the process flow diagram was completed and verified, the HACCP team listed all biological, chemical and physical hazards that are reasonably expected to occur at each step and has described the preventive measures that can control these hazards. For inclusion in the list, hazards are of such nature that their elimination or reduction to acceptable levels is essential to the production and sale of safe Refined Vegetable Oil. The team considered preventive measures, which can be applied for each hazard. Preventive measures relate to the actions and activities that are required to eliminate hazards or reduce their impact or occurrence to acceptable levels. More than one preventive measure may be required to control a specific hazard and more than one hazard may be controlled by a specified preventive measure. While conducting hazard analysis consideration has been given to the following:

a) The likely occurrence of the hazards and the severity of their

adverse health effects. b) The qualitative and the quantitative evaluation of the presence of hazards. c) Survival / multiplication of microorganisms of concern. d) Production or persistence in force of biological, chemical or physical agents, and e) Conditions leading to the above. Hazard analysis results for each product are given in HACCP Plan.

Determine critical control points (CCP)

The identification of a CCP in the HACCP system is facilitated by applying the decision tree based on Annexure A6. All hazards that may be reasonably expected to occur, or be introduced at each step, have been considered. Training in applying the decision tree has been given to the team members. If a hazard has been identified at a step where control is necessary for safety, and no preventive measure exists at that step, or any other, then the product or process is modified at that step, or at any earlier or later stage, to include a preventive measure. Application of the decision tree has been applied to determine whether the step is a CCP for the identified hazard. HACCP plan based on CCPs identified for products are given.

Supporting Documents: Annexure- A6

ESTABLISHING CRITICAL LIMITS FOR EACH CCP

Since CCPs define the boundaries between safe and unsafe products, it is vital that they are set at the correct level for each criterion. The HACCP team has set the appropriate critical limits. Critical limits have been specified for each preventative measure. The limit fixed for each product is given in the Annex A7.

Supporting Documents: Annexure- A7

ESTABLISHING MONITORING SYSTEM FOR EACH (CCP)

Monitoring is one of the most important aspects of HACCP system. It is the scheduled measurement or observation of a CCP relative to its critical limits. The monitoring procedures are designed to enable detection of loss of control at the CCP and provide timely information for corrective action to regain process control before reaching a stage of product rejection. Data derived from monitoring is evaluated regularly to carry out corrective actions. The frequency of monitoring has been specified which is sufficient to guarantee that the CCP is under control. The monitoring procedures for CCPs are done rapidly because they relate to online Processes and there will not be time for lengthy analytical testing. Physical and chemical measurements have been preferred to microbiological testing because they may be done rapidly and can often indicate the microbiological control of the product. All records and documents associated with monitoring CCPs are signed by the person (s) doing the monitoring and by a responsible reviewing official of A.P.ORGANICS (P) LTD The monitoring procedures and frequency of monitoring are given in HACCP Plan.

Supporting Documents: Annexure-A7

CORRECTIVE ACTIONS/ REMEDIAL MEASURES FOR EACH CONTROL POINT (CCP)

Specific corrective actions have been developed for each CCP in the HACCP system in order to deal with deviations when they occur. The actions taken ensure that the CCP has been brought under control. Corrective action also occurs when monitoring results indicate a trend towards loss of control at a CCP. Action is taken to bring the process back into control before the deviation leads to a safety hazard.

VERIFICATION PROCEDURE INTERNAL AUDIT

HACCP system includes verification procedures for assuring that the HACCP system is being complied with on day-to-day basis. This is done most effectively by using internal quality audit methods to ensure that the HACCP system is working correctly. Monitoring and auditing methods, procedures and tests, including random sampling and analysis, are used to determine if the HACCP system is working correctly. Frequency of audit and verification are kept at appropriate intervals to validate the HACCP system.

Supporting Documents: Internal Audit File

MRM
Management Review meetings are conducted after Internal Audit (generally threefourth months) and whenever required. This meeting includes the review of all operational and supporting functions of HACCP, which shows the effectiveness, and maintenance of HACCP. HACCP Team reviews HACCP at least in 3-4 months or as earlier as per need. Review also includes the assessment of the opportunity for improvement and the need for changes. As CCPs are monitored regularly and also verified .As much emphasis is given on CCPs in MRM.They are the key aspects to control the HAZARDS. During the Internal Audits also, CCP are reviewed for their monitoring, Verification etc. As well Procedure has been developed for Validation of HACCP Plan and CCPs at a specific intervals. VERIFICATION activities include: a) Review of the HACCP system and its records b) Review of deviations and product dispositions: Immediately after the occurrence of deviations. c) Validation of CCPs: as stated in procedure

d) Validation of established critical limits when product formulation changes or processes parameter changes.

Supporting Documents: MRM file & Validation File

DOCUMENTATION Records relating to the HACCP System

Efficient and accurate record is maintained for the application and maintenance of HACCP system. Records are kept of all areas, which are critical to product safety to demonstrate that the HACCP system is in compliance with the documented system. Records help in providing a basis for analysis of trends as well as for internal investigation of any food safety incidents, which might have occurred. Important documentation and records are: HACCP Manual Procedural Manual Format Manual Quality Plan Responsibility & Authority Manual Master List Supporting Manual and Work Instructions Training File Internal Audit file Rejection, Non-Conforming Materials and Complaint File MRM CCP Monitoring Registers Others

Document & Data change: Changes to above mentioned documents and data are reviewed and approved by the same authority that carries out the initial approval. He should have relevant information regarding for the reasons/ need for modification. The Team Leader /M.R. reissues these documents and records (Table 1). However amendments activities in standards/ specifications, checklists are maintained by QCM. Obsolete documents and datas are removed from all points of use and are destroyed after having

the copy of each. Obsolete documents are retained for legal or knowledge sake and are identified by stamp title OBSOLETE and filed in Obsolete File. In general individual personnel and departments are responsible for the long-term retention of the records, which they generate. A procedure is being generated for control of records.

Supporting Documents: Procedural Manual

A procedure has been documented for control of documents and Records to ensure effective control. Documents & Records relating to the system are retained for periods defined in the procedure. All records are identified by unique code. The identification, collection, indexing, filling, storage, maintenance and disposition are carried out as per procedure. The retention time of records is fixed taking consideration of regulatory / statutory requirements and product liability and the retention periods are maintained. Records are legible and easily identifiable and shall be easily accessible as when required. Records are controlled as per documented procedure. Where specified in the contract, records are made available to customers representative. Table 1 Matrix for Responsibility and Authority of Documentation Control Sl. Document name Document No. HP PR QP FM SM ML RM WI Prepared By Team Team Team Team Team Team Team Team Team Approved By Director Director Director Director Director Director Director Director Director No. 1. HACCP Manual (PRP + HACCP Plan) 2. 3. 4. 5. 6. 7. 8. 9. Procedural manual Quality Plan Format Manual Supporting Manual Master List Responsibility & Authority Manual Work Instructions Other Documents and Records (If required)

Review: Documents of all type are reviewed by the designated authority before approval & changes if any are incorporated. Approval: After thorough review, document shall be approved by designated authority. Issued: All documents are issued and controlled by Team Leader/M.R. He assigns an issue no. /rev. no. and ensures that date of issue /effective date is same as date of release for implementation.

PROCEDURES
Wherever essential and required documented procedures have been established which shows and maintain integrity of the standard. These procedures are also guidelines for manufacturing product without deviation and delivery to the end user.

Supporting Documents: Procedural Manual

PRODUCT MARKING or LABELING and RECALL

1. The product is marked with PKD Month/year; batch No for identification of the product. 2. All cartoons / package / containers are identified by indicating date, batch number, weight, brand name / product name, rate etc. 3. The batch no/Packing Date of Cartoon is written on the bill of the product, issued to the customer for marketing and carbon copy is kept within premises. 4. If at any stage it is found, that the product is of substandard as per our parameters following steps are taken to recall the product: To trace out the party/parties, where the material is sent. Inform the party/parties by e-mail/fax/ over telephone with an instruction not to sell that particular material.withdrow from their sales counter. Bring the material at the plant; send that material to processing for rectification.

MAINTAINING THE HACCP SYSTEM

On the basis of MRM results, Verification results; Changes to the organizations food safety, Changes to the activities performed by the organization, effecting food safety. The HACCP system is being updated and maintained on regular basis.