Code:

BCIP G. Critical Control Point

CRITICAL CONTROL POINT 1 :

Product Cook (time and temperature)

PROCESS STEP:
Product Cook (Batch) – fat containing products

HAZARD:
Biological (Vegetative Pathogens)

CRITICAL LIMIT:
Product is heated for not less than 1.2 continuous seconds at a temperature
not less than 82.20C.

MONITORING ACTIVITY/FREQUENCY:
Temperature: Product temperature, at the coldest point, is continuously
recorded on a cook temperature chart.
Kettle Operator to ensure that every batch reaches the
temperature of 82.20C by looking into the temperature
displayed on the panel view then to record it into cooking
sheet.
Time: Team Leader/Line Supervisor to verify and document the timer
setting at beginning of each shift and the end of production.

CORRECTIVE ACTION ACTIVITY:

Under processed cheese shall be reheated to achieve a temperature of 85 0C.
If the product is found to be undercooked based on document review, all the
affected product shall be placed on category I Hold, and notify Quality Control
to determine disposition.
Hold/Released documentation is required.
Corrective action must be documented.

RESPONSIBILITY: (Monitoring and Corrective Action)

Designated, trained employee:
- Kettle Operator
- Product Assurance/QC Inspector
- Team Leader/Line Supervisor
RECORD/RESPONSIBILITY/LOCATION

RECORD RESPONSIBILITY LOCATION

Cook Temperature Charts Prod. Spv Production Office
Cooking Sheets Kettle Operator Production Office
Thermometer Calibration Log(s) M/S Crew M/S Office
Hold and Released Records QSS Laboratory QS Office
Corrective Action Records Prod. Spv/QC Coord. Production/QC
Verification Records Prod Spv Production Office

MINIMUM CCP VERIFICATION ACTIVITIES :

Production Supervisor/Production Line Supervisor or designated Staff
reviews and signs all process records at least daily.

HACCP PLANT VERIFICATION ACTIVITIES :

Thermometer calibration logs review every month to demonstrate control.
Verify cooker timer setting (for the actual cook time) and the accuracy of hold
time with a stopwatch at least weekly. Note: Record the time as ± 1.0-second
Verify accuracy of temperature monitoring device at least weekly.
Production Supervisor reviews records monthly to demonstrate control.

SCOPE :
CCP 1 covers Batch Cooking – In process and to be applied to all
products listed at form K

CRITICAL CONTROL POINT 2 :

 Proper addition of nisin

PROCESS STEP :
Nisin addition to Pasteurized Process Cheese

HAZARD :
Biological (Proteolytic and Non-proteolytic Clostridium botulinum)

CRITICAL LIMIT :
Amount of Nisaplin added to each batch (see attached table). No more than
the maximum local legal limit allowed (500 ppm of Nisaplin)

MONITORING METHOD/FREQUENCY :
Weight of Nisaplin every batch and record on ingredient weighing sheet.

CORRECTIVE ACTION ACTIVITY :

If amount of Nisaplin is less than the critical limit, add more nisaplin or divert
product and reprocess. If the amount of Nisaplin added exceeded the critical
limit, analyze product to ensure local legal limit not exceeded. If finished
product does not meet Nisaplin concentration requirement, place all affected
product on Category I Hold, and notify Quality Control Manager to determine
disposition.
Hold/Released documentation is required.
Corrective action must be documented.

RESPONSIBILITY : (Monitoring and Corrective Action)

Designated trained employee :
- Ingredient Weigher

RECORD/RESPONSIBILITY/LOCATION

RECORD RESPONSIBILITY LOCATION

Ingredient Weighing Sheet Ingredient Operator Production Office
Hold and Released Records QSS Laboratory QS Office
Corrective Action Records Prod. Spv/Qc Coord. Production/QC
Verification Records Prod Spv Production Office

MINIMUM CCP VERIFICATION ACTIVITIES :

Production Supervisor/Production Line Supervisor or designated Staff
reviews and signs ingredient weighing sheet at least daily.

HACCP PLAN VERIFICATION ACTIVITIES

Review scale and calibration record monthly to demonstrate control.
 Production Supervisor reviews records monthly to demonstrate control.

SCOPE :
CCP 2 covers Material Preparation & handling and to be applied to all
products listed at form K

No CODE NAME BATCH SIZE NISAPLIN

ADDED
1. BL03 Spreadable Cheese 5kg  58 kg 8 gr

CRITICAL CONTROL POINT 3 :

In Line filtering

PROCESS STEP :
In-line Filtration

HAZARD :
Physical - Extraneous Matter

CRITICAL LIMIT :
All products flow through an intact 0.8-mm size of stainless steel filter
Abnormal Critical Limits for one (1) shift (8-hours) are as follow:
Extraneous Matter Amount max
Plastic 10
Hard Plastic 3
Stone 10
Wood 5
Rubber 5
Foil 10
Metal 1
Whenever detect of extraneous matter above those limits, corrective action
need to be initiated

MONITORING METHOD/FREQUENCY :
All products pass through the filter.
Team Leader/line Supervisor to record amount and type of extraneous matter
found at least every shift.

CORRECTIVE ACTION ACTIVITY :

Whenever detect of extraneous matter above the limits, production
supervisor to observe the root cause and define the corrective action to
eliminate extraneous matter found.
If filter is not intact or in place during verification, put the product produced
 since the last acceptable check on Category II hold, stop the process, and
replace filter. Notify Quality Control to determine disposition.
If any hazardous extraneous matter is found in product, elevate hold to a
Category I hold. Notify Quality Control to determine disposition.
Hold/Released documentation is required.
Corrective action must be documented.

RESPONSIBILITY : (Monitoring and Corrective Action)

Team Leader/Line Supervisor/Production Supervisor

RECORD/RESPONSIBILITY/LOCATION

RECORD RESPONSIBILITY LOCATION

Filter log Packaging Operator Production Office
Hold and Released Records QC Coordinator QC Office
Corrective Action Records Prod. Spv/QC Coord. Production/QC
Verification Records Prod Spv Production Office

MINIMUM CCP VERIFICATION ACTIVITIES :

Production Supervisor/Production Line Supervisor or designated Staff
reviews and signs record daily.
Visual inspection of the filter integrity every day of operation to demonstrate
process control.
Upon installation of new filter, verify correct mm size/stock item number.

HACCP PLAN VERIFICATION ACTIVITIES:

Production Supervisor reviews records monthly to demonstrate control.

SCOPE :
CCP 3 covers Batch Cooking – In process and to be applied to all
products listed at form K