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Prepared : Name / Sign / Date MR / Doc. Type Manual /01Apr07 PS / Doc. No. FSM-BB-01

Food Safety Manual

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Bhole Baba Dairy Industries Ltd.

Address Aligarh

Amendment Status
Revision Status Date
00 01.04.07

Description of Revision
First Issue

Prepared By Date
MR 01.04.07

Reviewed By Date
PS 01.04.07

Approved By Date
MD 01.04.07

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0.

Profile Bhole Baba Dairy Industries Limited (BBDIL) situated at Aligarh (Dist - Aligarh of Uttar Pradesh) is having a pollution free environment and is blessed with a rich source of MILK with potential for multifold increase in milk production. The milk available is surplus for converting into value added products. The surplus milk available from the various Milk sources in the milk-shed area is about 0.4 million liters per day as of now and proposes to reach 1 million towards the end of the year 2007. BBDIL plans to set up a wide network of Bulk Coolers to gradually encompass its area of procurement as one of the perspectives towards continual improvement in the quality of incoming milk. This is to ensure procurement of best quality milk by providing immediate chilling facility at village level. The results of such integrated efforts are aimed at sharing with the valued customers of BBDIL and the society at large. The layout of the entire factory complex at Aligarh has been designed to have a green belt around the factory so that the entire atmosphere is dust and pollution free. The total covered area of the main factory building, including utilities, administration block & guesthouse (in process), is set up on a picturesque landscape. The plant houses the State-of-Art Technology both in equipment and manufacturing processes. BBDIL has been very closely associated with Westfalia Separators AG, Germany who has supplied the entire package of equipment for manufacture of Acid Casein. Lactose Plant and Separators have been procured from pioneers in Dairy Industry like Alfa Laval. BBDIL has its entire plant of NF/UF set up on a turnkey basis by APV Invensys

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At the well automated BBDIL, the milk reception and pre-processing is planned to begin from the keyboard of the computer and carries on through various stages till the final product has been produced. The present products being manufactured at BBDIL are Acid Casein, Lactose, Whey Protein Concentrate, Skimmed Milk Powder & Ghee Presently the company is concentrating to produce nutritionally superior, hygienically safe and economically viable products. On export front company has already created a strong base in US & Europe by exporting Skimmed Milk Powder and proposes to continue doing so even strongly by taking its other products like Casein, Lactose & Whey Protein Concentrates to the World Market. Besides this, the Company is eagerly looking forward and preparing for opportunities to export its products in the emerging markets in China & Japan. To achieve this ambitious plan the main agenda will be: PRODUCT SAFETY AND QUALITY.

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1. 1.1

Scope General

Bhole Baba has developed and implemented the Food Safety Management System (FSMS) described in this manual to help us to operate with increased effectiveness, efficiency, consistency and customer satisfaction. Our QMS utilizes the process approach and quality management principles contained in the international standards ISO 22000 to enhance our ability to continually improve. 1.2 Application

Our FSMS complies with all applicable requirements contained in ISO 22000, covers the following scope: Products Skimmed Milk Powder Casein & Derivatives Lactose Whey Protein Concentrates Ghee 1.3
Organization Structure

Processes Manufacturing Packaging & Dispatch.

Site (s) List the site address

Appendix A

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2.1

Food Safety policy

We, At Bhole Baba Dairy Industries Limited, Are Committed To Manufacture & Supply Quality Food Products To Achieve Customer Satisfaction, Through Continual Improvements In Products, Processes & Systems.
Our policy statement indicates our commitment and focuses on what is important to us as an organization: achieving customer satisfaction; and it prescribes the method by which we accomplish this: by continually improving processes, and services to ensure they consistently meet or exceed requirements. Moreover, our policy statement acts as a compass, providing the direction and a framework for establishing key performance measures and related improvement objectives.

2.2

Food Safety objectives

Our overall goal is to achieve our Food Safety policy, and maintain the integrity of and continually improved FSMS. At the Management level, MRC will monitor and measure performances in the areas outlined below and, where needed, establish measurable improvement objectives. -- -- --Insert the various objectives

At the operational level, all Staff members will monitor and measure performance of processes within their area(s) of responsibility.

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3. Reference Documents (including Statutory and Regulatory requirements) The following external documents contain provisions which, through reference in this manual, constitute provisions of our FSMS:

ISO 22000 Food Safety Management System Requirements for organizations through out the food chain. List all the statutory requirements. Prevention of Food Adulteration Act 1954, Edition 2005 IS 10500, IS-14543 Water---Agmark Guidelines CAC/RCP 57-2004, Code of Hygiene Practice for Milk and Milk Products CAC/RCP 56-2004Code of Practice for the Prevention and Reduction of lead Contamination in Foods. Specify the Registration numbers with various statutory bodies. 4. S. No. 1. Control on out-sourced Process: Process Calibration Look out for any more out sourced product/ process. Control Mechanism ISO/IEC 17025 certified Laboratory NABL Accreditation

5. Sr. 1 2 3 4 5 6

Food Safety Team: Designation President (Operations) Manager (Quality Control) Manager (QMS) (HACCP Co ordinator) Manager (Production) Manager (Engineering) Sr. Microbiologist Competence Criteria Skill 1 Skill 2 Skill 3

Skill 1: Expertise in different aspects of food safety ranging from farm to fork. Skill 2: Awareness of the requirements of HACCP Skill 3: Experience in Food Industry (min. 2 yrs)

6. A

Appendix: Organization Structure

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List of Procedures, which define the key processes for implementing our quality policy. Note: Procedure Document Control contains procedures governing the control of these and other FSMS documents. Description of compliance to ISO 22000 requirements

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Appendix A Organization Chart

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Appendix B List of Procedures

S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Description Procedure for document control Procedure for record control Procedure for Audits Procedure for management review meeting Procedure for Identification, Traceability & Recall Procedure for Corrective actions Procedure for Preventive actions Procedure for interaction with customers (complaints, feedback) Procedure for emergency preparedness / contingency HACCP Manual of Raw Milk Reception HACCP Manual of Ghee HACCP Manual of Skim Milk Powder HACCP Manual of Casein HACCP Manual of Whey Processing HACCP Manual of Lactose HACCP Manual of Whey Protein Concentrate Current Good Manufacturing Practices (CGMP) Procedure for Standard Sanitary Operating Procedures (SSOP) Procedures at Engineering Stores Procedures at Packing Material & Finished Goods Stores Procedures for Mechanical Maintenance Procedures for Electrical Maintenance Procedures for Instrumentation & Control Procedure for Human Resource & Personnel Related Tasks Procedure for Training Document No. QS/P/001 QS/P/002 QS/P/003 QS/P/004 QS/P/005 QS/P/006 QS/P/007 QS/P/008 QS/P/009 HACCP/01 HACCP/02 HACCP/03 HACCP/04 HACCP/05 HACCP/06 HACCP/07

STR/ENG/P/001 STR/PMFG/P/001 ENG/MECH/P/001 ENG/ELE/P/001 ENG/I&C/P/001 HR/HR/P/001 HR/TRG/P/001

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S. No. 26. 27. 28.

Description Procedure for Purchase of all material except milk Procedure for Purchase of milk Procedure for evaluation of suppliers

Document No. PUR/PUR/P/001 PUR/PUR/P/002 PUR/PUR/P/003

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Appendix C Adequacy Matrix (FSMS vs. ISO 22000)

CLAUSE OF IS/ISO 9001:2001 REQUIREMENTS STANDARD OF THE SYSTEM DOCUMENTATION

4 4.1 4.2 4.2.1 4.2.2 4.2.3 5 5.1 5.2 5.3 5.4 5.5 5.6 5.6.1

Food Safety Management system(title only) General Requirements Documentation Requirements(title only) General Control of Documents Control of records Management Responsibility(title only) Management Commitment Food Safety Policy Food Safety Management System Planning Responsibility and authority Food Safety Team Leader Communication (Title Only) External Communication

--FSM-BB-01 --FSM-BB-01 QS/P/001 QS/P/002 --FSM-BB-01 FSM-BB-01 FSM-BB-01 HR/JR/P/001-009 Mr. --Subject
Suppliers & Contractors Customers Food Authorities Other stake holders

Responsible Mr. Mr. (QS/P/008) Mr. Mr.

5.6.2 5.7 5.8

Internal Communication Contingency Preparedness & response Management Review (Title Only)

Meetings, Training Programs, Circulars, EPBX, Notice Boards, Work Instructions etc. QS/P/009 ---

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CLAUSE OF IS/ISO 9001:2001

REQUIREMENTS STANDARD

OF

THE

SYSTEM DOCUMENTATION

5.8.1 5.8.2 5.8.3 6 6.1 6.2 6.2.1 6.2.2 6.3 6.4 7 7.1 7.2 7.2.1 7.2.2

General Review Input Review Output Resource Management (title only) Provision of resources Human Resources (title only) General Competence Awareness and Training Infrastructure Work Environment Planning & realization of safe products (title only) General Pre-requisite program(title only) General requirements Infrastructure & Maintenance Programs Operational PRPs Preliminary steps to enable Hazard Analysis (title only) General Food Safety Team Product Characteristics Raw materials, ingredients & product contact materials

QS/P/004 ------HR/HR/P/001 HR/TRG/P/001 ------------ENG/MECH/P/001 ENG/ELE/P/001 ENG/I&C/P/001 Refer List of PRP ----FSM-BB-01 --STR/ENG/P/001 STR/PMFG/P/001 HACCP/01-07 HACCP/01-07

7.2.3 7.3 7.3.1 7.3.2 7.3.3 7.3.3.1 7.3.3.2 7.3.4 7.3.5 7.3.5.1

End Product Characteristics Intended Use Flow Diagrams, process steps & --control measures (Title Only) Flow Diagrams HACCP/01-07

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CLAUSE OF IS/ISO 9001:2001

REQUIREMENTS STANDARD

OF

THE

SYSTEM DOCUMENTATION

7.3.5.2 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.5 7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.6.5 7.7

7.8 7.9 7.9.1 7.9.2 7.9.3 7.9.3.1 7.9.3.2 7.9.4 7.9.5

Description of process steps and control measures Hazard Analysis (title only) General Hazard identification & determination of acceptable levels Hazard Assessment Identification & Assessment of control measures Design & Redesign of operational PRP Design & Redesign of HACCP Plan (Title only) HACCP Plan Identification of CCPs Determination of critical limits for CCPs System for the monitoring of CCPs Actions when monitoring results exceeds critical limits Updating of preliminary information and documents specifying the PRP and HACCP Plan Verification planning Operation of the food safety management system (Title only) General Traceability System Corrections & Corrective actions (Title only) Corrective actions Corrections Handling of potentially unsafe products Recalls

HACCP/01-07 --HACCP/01-07

Refer List of PRP --HACCP/01-07

QS/P/001 QS/P/004 Refer the procedure for verification ----QS/P/005 --QS/P/006 Refer the procedure for control of NCP Refer the procedure for control of NCP QS/P/005

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CLAUSE OF IS/ISO 9001:2001

REQUIREMENTS STANDARD

OF

THE

SYSTEM DOCUMENTATION

8 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.4 8.5 8.5.1 8.5.2

Verification, validation and improvement of food safety management system (Title only) General Monitoring and measuring Food safety management system verification (Title only) Internal Audit Evaluation of individual verification results Analysis of results of verification activities Validation of control measure combination Improvement (Title only) Continual Improvement

----ENG/I&C/P/001 --QS/P/003 Refer the procedure for verification QS/P/004 HACCP/01-07 --QS/P/004

Food safety management system Refer the procedure for verification updating QS/P/001

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