Oriental Fruits HACCP Manual

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ORIENTAL FRUITS (PVT) LTD. Rev. #:00

HACCP Manual Doc. #: HM
Rev. Date: 18-04-2018
Activity Designation Signature

Prepared & Reviewed By Manager Quality Assurance
Approved By General Manager
Date Doc. # Rev.# Reason of change Approved By
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Authorized By Issue No. Review Date Next Review Date Page File Reff: PCS 00040/02
TariqJawed 1 Nov. 2018 Aug. 2019 1 of 1 HACCP Manual
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Rev. #:00
ORIENTAL FRUITS (PVT) LTD. Doc. #: HM
HACCP Manual Rev. Date: 18-04-2018
Table of Contents
Ser # Contents Page#

0.0 Revision History of HACCP Manual 01
1. Purpose & Scope of HACCP Manual 03
2. Organization 04
3. Definitions 05
4. Current Good Manufacturing Practices 06
5. Sanitation Standard Operating Procedures 07
6. HACCP Plan Development & Implementation 08
7. HACCP Team 09
8. Product Description 10
9. Process Flow Diagram 11
10. Hazard Analysis 14
11. Establish CORRECTIVE actions 18
12. Verification and validation procedure 19
13. Establish Records 20
14. Recall & Complaint Procedure 21
15. Training 22
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1- Purpose & Scope of HACCP Manual

This manual is based upon the principle that food safety is best ensured through
the identification and control of hazards in the production, manufacturing and
handling of food described in the Hazard Analysis and Critical Control Point
(HACCP) system.
This standard manual enable to implement a food safety program based upon the
HACCP concepts. The food safety program is to be implemented and reviewed by
top management and is subject to periodic audit by a suitably qualified food
safety auditor.
The scope of our “HACCP-food safety program” is Manufacturer of TROPICAL.
Organization takes the HACCP program as a technique, process & a management

system for the assurance of food safety that identifies, evaluates and control
hazards to ensure food safety.
HACCP is applied throughout the food chain from primary production to final
consumption .We use it an insurance against food borne incidents and diseases.
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Rev. Date: 18-04-2018
2-Organization
Oriental fruit (OFL) is processing of TROPICAL line production capacity is 160 tons
of fruit per day (20hrs)
TROPICAL current capacity is 150 ton of fruit per day (20hrs)
It is built on the foundation of producing quality TROPICAL fruit products.
OFL being the pioneer in the field of TROPICAL production in Pakistan.
At OFL soon TROPICAL line will also be in running position.
OFL is aimed to produce quality products fowling international standard of quality

at every step of production. OFL is set to produce sustain production at highest
quality and will follow all food safety measures at its facility to produce for its
customers.
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Rev. Date: 18-04-2018
3.0 –Definitions
Following are the terms related to HACCP system & our industry for personnel
clarity so that they clearly understand these effective documentation,
development and implementation of system:
HACCP System definitions

Acceptable level The presence of a hazard, which does not pose the likelihood of causing an unacceptable health risk.
Control To take all necessary actions to ensure and maintain compliance with criteria established in the HACCP
plan.
Control point Any point in a specific food system at which loss of control does not lead to unacceptable health risk.
Critical control point A point at which loss of control may result in an unacceptable health risk.
Critical limit A value that separates acceptability from unacceptability.
Critical limit The maximum or minimum value to which a physical, biological, or chemical parameter must be
controlled at a critical control point to minimize the risk that the identified food safety hazard may
accrue.
Corrective action The action to be taken when the results of monitoring the CCP indicate a loss of control.
Deviation Failure to meet a required critical limit for a critical control point
Food Hazard Any biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the
absence of its control.
Hazard A biological, chemical or physical agent or condition with the potential to cause harm /adverse health
effect.
Hazard A biological, chemical, or physical property that may cause an unacceptable consumer health risk.
Hazard Analysis The process of collecting and evaluating information on hazards and conditions leading to their
presence to decide which are significant for food safety and therefore should be addressed in the
HACCP plan
Monitor A planned sequence of observation or measurements of critical limits designed to produce an accurate
record and intended to ensure that the critical limit maintains product safety. Continuous monitoring
means an uninterrupted record of data.
Preventive measure Action to exclude destroys, eliminate, or reduce a hazard and prevent recontamination through
effective means.
Risk An estimate of the likely occurrence of a hazard.
Shelf Stable A hermetically sealed and when stored at room temperature should demonstrate any microbial growth.
Product
Step Any location or stage in food production and / or manufacture their receipt and / or production,
harvesting, transport, formulation, processing manufacturing, storage, etc. as identified in the flow
diagram.
Validation That element of verification focused on collecting and evaluating scientific and technical information to
determine whether the HACCP plan, when properly implemented, will effectively control the identified
food hazards.
Verification The use of methods, procedures, or tests in addition to those used in monitoring to determine
compliance with the HACCP plans and / or whether the HACCP plan needs modification in order to
enhance food safety.
Verification Methods, procedures, and test used to determine if the HACCP system in use is in compliance with the
HACCP plan.
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Rev. Date: 18-04-2018
4 –CURRENT GOOD MANUFACTURING PRACTICES

Top Management develops and implements GMPs procedures within the plant
For further detail check
Procedure for Premises Cleaning QP-14
Procedure for Personnel HYGIENE QP-15
Procedure for Pest Control QP-16
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Rev. Date: 18-04-2018
5-Sanitation Standard Operating Procedures
Top Management adopts effectively a sanitation control system within the plant.
We have developed and implemented SOP successfully that addresses sanitation
conditions and practices before, during and after processing. This SOP Manual is
designed to cover the following requirements:
1. Safety of water that comes into contact with food Packaging
2. Condition and cleanliness of food Packaging contact surfaces
3. Prevention of cross contamination from insanitary objects to food packaging

and contact surfaces
4. Maintenance of hand washing, hand sanitizing and toilet facilities
5. Protection of food packaging material and contact surfaces from adulteration
6. Proper labeling, storage and use of toxic compounds
7. Control of employee health conditions
8. Exclusion of pests
Admin Manager is responsible for the implementation and control of these

sanitary requirements. General Manager is responsible for monitoring the
conditions and practices during processing with sufficient frequency and
commitment to ensure the conformance with conditions and practices ate met.
For further detail check
Procedure for Premises Cleaning QP-14
Procedure for Premises Hygiene QP-15
Procedure for Pest Control QP-16
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Rev. Date: 18-04-2018
6.0- HACCP plan Development & Implementation
To ensure product quality and safety HACCP system provides a systematic, preventive approach
to the control of raw materials, processes, the processing environment, packaging and the
distribution system. Hence the top management establishes, develops and designs the HACCP
system to determine potential problems, establish process specifications and was in which
hazards are controlled. In the plant,
Top management implemented HACCP plan in the following logic sequence:
1 -Assemble the HACCP team
2- Describe the Product, its intended use & distribution
3 -Construct a detailed Flow Diagram of the Process
4-Conduct on-site verification of Flow Diagram
5-List all potential hazards associated with each step, conduct a hazard analysis and consider
any control measures to control hazards (Principle 1)
6-Determine critical control points (Principle 2)
7-Establish critical limits for each CCP (Principle 3)
8-Establis a monitoring system for each CCP (Principle 4)
9-Establis corrective Actions for CCP Deviations that may occur (Principle 5)
10-Establish verification procedures (Principle 6)
11-Establish record keeping & documentation (Principle 7)
12-Determine what training needed for all staff including employees, supervisors and quality
Assurance people so all understand what HACCCP means to the premises and to them.
HACCP plan is a written document which is based upon the principal activities of HACCP and
which delineates the procedures to be followed to assure the control of a specific process or
procedure.
For detail check “HACCP” plan. HM-03
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Rev. Date: 18-04-2018
7-HACCP Team
Top management assembles of individuals in the form of a HACCP team that have
a specific knowledge expertise appropriate to the product, production line and
processes. It is the group responsibility to develop the HACCP plan and they are
also responsible to:
1-identify potential hazards.
2-assign levels of severity and risk (likelihood of occurrence).
3-identify critical control points; recommend control measures, critical limits and
procedures for monitoring and verification.
4-recommend appropriate corrective actions when deviations occur.
5-recommend or conduct investigations and/or research related to the HACCP

plan (if information is not available).
aaA
HACCP team defines the boundaries of the HACCP plan, both from a starting and
finishing perspective, and from an inclusions perspective (HACCP plan includes
quality aspects as defined by the finished product specification, or is it restricted
to food packaging safety-biological, chemical, physical Hazards). While including
other requirements in our overall documentation, the priority of HACCP program
is food safety.
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See HACCP team HM-01
All Personnel are responsible to follow four-step quality assurance cycle. In which
they:
 Plan the food packaging production operations, how it can be done safely
 Organize and learn to do each production step and any related tasks
correctly
 Operate and do tasks according to the procedures and standards of this
manual, and immediately check that they have met necessary standards at
each production step
 Measure and evaluate what they have done, and make suggestions to
management as to how tasks and steps can be improved with a higher
degree of quality assurance
If a person does not know how to do a task in the production of food

packaging safely, he will stop his working, ask and learn how to perform it
and then return to his job. It is the responsibility of the MR to train the
employees in accordance with the procedure “Hunan Resource QP-04”.
It is responsibility of the employees to monitor their own work. In case of a

mistake, they will take any necessary action immediately to assure the
production of safe food. In case of potentially hazardous food handling
practices, potentially hazardous conditions, or potentially hazardous foods,
they are responsible to stop the working and report to General Manager,
immediately. Actions are taken in accordance with the procedure
“Improvement QP-12” to resolve the problems. Top management is also
notified as soon as possible if the situation is not corrected and there is still
a hazard.
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Flow diagram of logically HACCP plan development and implementation
Management commitment & understanding 1
Assemble HACCP Team 2
Describe product & identify intended 3
Construct flow diagram 4
On site verification of flow diagram 5
Identify hazards & describe preventive measures 6
Identify critical control points 7
Establish a critical limits for each step 8
Establish a monitoring system for each CCP 9
Establish corrective actions for deviation that may occurs 10
Establish verification procedure 11
Establish record keeping & documentation 12
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Rev. Date: 18-04-2018
HACCP team describes the product as under:
Tropical Specification
Characteristics PSQCA Specification
Composition Natural TROPICAL
Method of production Pulp De-stoner, finisher 1, Thermo break, finisher
2, Homogenizer, Sterilizer, Filling and final storage.
Packing Steel drums net wt =210kg, gross wt =228Kg, with

aseptic poly bags.
Distribution Through refer containers at 5 to 10oc
Storage condition At 5 to 10oc
Shelf life 02 year at 5 to 10oc
Handling before use Clean and safe
Regulatory requirement PSQCA Specification
Intended Use For Drinks, Juices, Nectars etc.
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Rev. Date: 18-04-2018
09- Process flow diagram (TROPICAL)
150 ton per day

Start
1) Product Arrives in
receiving area/weigh
scale
2) Arrival checks
completed for fruit
meet QA specs y/n
4) Rejected vehicle
3) Fruit Ripening go back to……….
& un-loading
ripening
5) Fruit unloading at
Grader partial manual
operation at this stage.
6) The Fruit sorting

conveyor removing black
spot cutting work.
7) Fruit washing Tub
Fruit washing with water.
8) Bucket Elevator to move

the fruit up wards for de-
stoning/chopping
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Rev. Date: 18-04-2018
9) Brush washer fruit

washing with brushes
by spraying R.O
water.
10) De-stoners 1, 2&3 11) Choppers 1 &2
12) Finisher 1
13) Thermo break
14) Finisher 2
15) Homogenizer
CCP 16) Sterilization temperature

of the PULP must reach 104oC 17) If Time or
to 107oC for 30 sec (holding temperature are not met
time) in order to kill microbes product is taken in balance
deactivate PME. tank for reprocess.
18) TROPICAL is filled in

drums of 210 kg after
approval of QA and stored
in cold storage at 4 to 10
C10oC. Pulp passed through 0.5 mm
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Filter before filling.

END
Rev. Date: 18-04-2018
Hazard Analysis
Monitoring
Corrective
Measure
Records
Process
Control
Actions
Hazard
Critical
Limits
Step
What When How Who
Visual Inspection
Temperature log
104oC to 107oC
Temperature
Temperature
Continuously
Pathogenic
Operator
Sterilizer
Bacteria
temperature
sheet
Maintain
__________________
____________________
Prepared by
Approved by
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Rev. Date: 18-04-2018
10- Hazard Analysis

In a HACCP system, it is the responsibility of HACCP team to indentify and assess
hazards for their risk factory. They are trained and aware and about hazards that
have the potential to cause harm to:
 The Consumers (Safety Aspect)

 The products (Quality Aspect)
 The Presentation of product (Commercial Aspect)
HACCP team identifies hazards in to following categories:
 Biological Contamination – Including presence of pathogens, parasites etc.

 Chemical Contamination - Including presence of either naturally occurring
chemicals such as Mycotoxins or added chemicals such as agricultural and
industrial chemicals.
 Physical contamination – Including glass fixture, plastic, etc.
 Quality or commercial faults- Including product composition faults,
packaging faults, etc.
It is essential to distinguish between hazards and risks. Hazards are qualitative /

quantitative whereas risk are qualitative / quantitative and thus indicate the
likelihood of a problem occurring. HACCP team is trained in this respect and ranks
the hazards as:
1. High
2. Medium
3. Low
Normally the sources of hazards are:
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1. Raw Material – which are likely to contain biological chemical and physical
contaminations
2. Process-Designed to inactive contamination create hazards when they fail.
3. Mishandling-Of materials or products by the handler.
HACCP team is responsible to work on GMPs to assure the realization of these

sources. T op management realizes the importance of GMPs to effectively
implement the HACCP program.
HACCP team has developed a written hazard analysis to determine the food
hazards that are reasonable likely to occur. They identify the control measures
with the application of those hazards are controlled. The written hazard analysis
consists of:
1. Identification of hazards
2. An evaluation of each hazard identified
3. Identification of control measures
4. Review of the current process
5. Identification of critical control points
HACCP team during the hazard analysis includes the food hazards, which are
introduced within or outside the plant. During evaluating the hazard, which is
likely to occur, the HACCP team gives consideration to the following:
1. Microbiological contamination
2. Parasites
3. Chemical contamination
4. Unlawful pesticides residues
5. Decomposition in the food packaging
6. Natural toxins
7. Unapproved use of food or color additives
8. Presence of undeclared ingredients
9. Physical hazards
HACCP team determines the effect of each on the safety of finished food.
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For further detail check “Hazard Analysis”HM-02

Rev. Date: 18-04-2018
11-Corrective Actions
Corrective actions are defined as procedures to be followed when a serious or
critical deficiency is assessed or when critical limits are exceeded at critical control
point corrective action are taken to eliminate the hazard created by deviation.
The HACCP team develops specific procedures for each critical limit of a critical
control point. This is due to variations in product and the diversity of associate
deviations this corrective action involve:
1. A statement of the problem

2. Procedures for handling of product
3. Identify the person responsible for the corrective action
4. Testing to establish the acceptability (if applicable)
5. Final disposition of product
6. Documentation and signatures
For further detail check the procedure “Improvement”.
When a deviation from a critical limit occurs and there is no proper corrective
action is taken by HACCP team that is appropriate for the deviation for the
deviation, then the HACCP team is responsible to:
1. Segregate and hold the product

2. Perform the review to determine acceptability
3. Take corrective action, when necessary with respect to the affected
product
4. Take corrective action when necessary to correct the cause of deviation
5. Perform timely verification
6. Records related to the corrective action taken are maintained
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Rev. Date: 18-04-2018
12-Verificaion and Validation
HACCP team is responsible to verify that HACCP system is implemented according
to the design. Verification consists of a periodic review to determine the overall
effectiveness of the HACCP plan. Both the HACCP team and HACCP auditor have a
role in verifying HACCP plan when it was developed. Verification activities include:
1. Review of any customer complaints

2. Calibration of process monitoring instruments
3. Review of the records that documents
4. Inspections of the facility as to conformance with the facility of HACCP plan
5. Sample collection and analysis to support inspectional observations
6. Physical, chemical, and sensory examinations for conformance
7. Testing for conformance with biological criteria
8. Inspection of the contract laboratory to ensure that the sample received for
analysis
HACCP team responsible for the validation of HACCP plan and ensure that it is
adequate to control food packaging hazards that are reasonably likely to occur
and this will be done at least once a year after implementation or alter the HACCP
plan in any way. These changes include the following:
1. Raw material or source of raw materials

2. Processing methods
3. Packaging
4. Finished product distribution system
5. Customer/ intended use of the product
The HACCP plan will be modified immediately whenever a deviation reveals that
the plan is no longer adequate to fully meet the requirement.
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Rev. Date: 18-04-2018
13-Establish Records
HACCP team prepares and maintenance the following records documenting the
HACCP system:
1. Written hazards analysis, HACCP plan & records related to GMP & HACCP
plan application including monitoring, verification &validation of HACCP
plan, CCP’s &corrective actions.
All records related to HACCP system should be retained for minimum an year.
All records must have, name, date, time of activity and signature of the individuals
performing the activity. For each critical control point HACCP team prepares that
demonstrates monitoring procedures and corrective action being taken.
Organization develops a strict record keeping system that demonstrates control

over critical control point and will:
1. Advise facility management of performance of a plants HACCP plan

2. Provide evidence of a proper and safe operation
3. Serve as a mechanism for including potentially serious problems and
assisting the responsible individual in the determination of proper
corrective action.
An efficient filling system is set up for all of these records and forms. All of the
records and forms in this filing system are accessible. Organization set up and
maintenance records keeping system that will provide the following information:
1. Early detection of areas of concern,

2. Isolation of a problem or potential problem is made easier,
3. Trends can be identified which may require more supervision,
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For detail check “control of documents” procedures.

Rev. Date: 18-04-2018
14-Recall & customer complaint procedure
In case of any serious complaint the withdrawal teams will be inform immediately
recall team members.
Team members Name Contact No.

Asst. General Manager Hanif 03034152556
Marketing Sale Aziz Ul Islam 03218899345
Manager Quality Ass. Tariq Jawed 03006030227
Store In- charge Ghulam Shabir 03016921720
Product will be hold in the market and stock by the order of Chief Executive
Officer & Managing Director/Asst. General Manager. Recall team will do detail
investigation about problem and following information will be obtain;
 Product name
 Batch detail
 Product code
 Type and quantity
 Problem nature
 Probable reason of occurrence
 Dispatch details
If the recall is of a serious nature, the Chief Executive Officer & Managing
Director/Asst. General Manager will ask M.Q.A to take the sample of the product
and analyze and report them.
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The product is destroyed /or the actions are taken as per 4.4 of control of Non-
confirming procedure for improvement QP-12 All the actions taken for recall are
discussed in management review meeting.
For further detail check procedure “control of non-conforming and Improvement”

Rev. Date: 18-04-2018
15-Training
M.Q.A is responsible to:
 Provide training for management and in-charge in pertinent in pertinent

food safety matters.
 Communicate the food safety program to all employees.
 Maintain a written training program &their records.
 Train employees with documented company rules with regard to hygiene
policy.
 Train those employees who are not literate.
 Provide additional training as necessary to ensure current knowledge of
equipment and process technology.
Training and continuing education for all employees are the most important part
of HACCP-based Quality Management. Employees are the individuals who carry
out the policies, procedure, and standards of the organization. They are given
information concerning food borne illness hazards and control so that to
understand the need for performing their jobs in a designated manner. All
employees are given instruction for good personal hygiene and proper methods
of hand washing during working.
Records are kept of employee participation in training activities and used monitor
employee development.
For further detail check the procedure “Human Resource”.
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1

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

Activity Designation Signature

Date Doc. # Rev.# Reason of change Approved By

Ser # Contents Page#

1- Purpose & Scope of HACCP Manual

The scope of our “HACCP-food safety program” is Manufacturer of TROPICAL.

Organization takes the HACCP program as a technique, process & a management

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

TROPICAL current capacity is 150 ton of fruit per day (20hrs)

It is built on the foundation of producing quality TROPICAL fruit products.

OFL being the pioneer in the field of TROPICAL production in Pakistan.

At OFL soon TROPICAL line will also be in running position.

OFL is aimed to produce quality products fowling international standard of quality

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

HACCP System definitions

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

4 –CURRENT GOOD MANUFACTURING PRACTICES

For further detail check

Procedure for Premises Cleaning QP-14

Procedure for Personnel HYGIENE QP-15

Procedure for Pest Control QP-16

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

1. Safety of water that comes into contact with food Packaging

2. Condition and cleanliness of food Packaging contact surfaces

3. Prevention of cross contamination from insanitary objects to food packaging

4. Maintenance of hand washing, hand sanitizing and toilet facilities

5. Protection of food packaging material and contact surfaces from adulteration

6. Proper labeling, storage and use of toxic compounds

7. Control of employee health conditions

Admin Manager is responsible for the implementation and control of these

For further detail check

Procedure for Premises Cleaning QP-14

Procedure for Premises Hygiene QP-15

Procedure for Pest Control QP-16

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

Top management implemented HACCP plan in the following logic sequence:

1 -Assemble the HACCP team

2- Describe the Product, its intended use & distribution

3 -Construct a detailed Flow Diagram of the Process

4-Conduct on-site verification of Flow Diagram

6-Determine critical control points (Principle 2)

7-Establish critical limits for each CCP (Principle 3)

8-Establis a monitoring system for each CCP (Principle 4)

10-Establish verification procedures (Principle 6)

11-Establish record keeping & documentation (Principle 7)

For detail check “HACCP” plan. HM-03

ORIENTAL FRUITS (PVT) LTD. Rev. #:00

1-identify potential hazards.

2-assign levels of severity and risk (likelihood of occurrence).

4-recommend appropriate corrective actions when deviations occur.

5-recommend or conduct investigations and/or research related to the HACCP

See HACCP team HM-01

If a person does not know how to do a task in the production of food

It is responsibility of the employees to monitor their own work. In case of a

Flow diagram of logically HACCP plan development and implementation

Management commitment & understanding 1

Assemble HACCP Team 2

Describe product & identify intended 3

Construct flow diagram 4

On site verification of flow diagram 5

Identify hazards & describe preventive measures 6

Identify critical control points 7