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HACCP PLAN

POTATO CHIP
Table Of Content
HACCP plan of Potato Chip is arranged by HACCP team in PT MRT base on 12 step of HACCP (BRCGS
Food issue 8 clause 2). Detail content in HACCP Plan can be seen on the table 1.
No Chapter Clause
1 HACCP Team Clause 2.1
2 Product Description Clause 2.3 and 2.4
3 Ingredients Description Clause 2.3
4 Packaging Description Clause 2.3
5 Flow Diagram Clause 2.5 and 2.6
6 Layout Production site Clause 4 and 8
7 Hazard Analysis Clause 2.7 and 2.8
8 Critical Limits Clause 2.9, 2.10, 2.11, 2.13
9 Verification Schedule Clause 2.12
Tabel 1. Table of Content
The structure of HACCP team is written in the table 2

Name Function in the HACCP Team Position


QWECDD HACCP Coordinator QA Manager
SDFER Team Member QC Manager
GBDET Team Member Production Manager
MKIEJR Team Member Rnd Manager
OELFVD Team Member Maintenance Manager
AWERS Team Member Purchasing Manager
WEDFV Team Member HR Manager
Table 2. HACCP Team
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Flow Process Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 1 of 18

1a 1b
Receiving Packaging Receiving Raw
Material Material
(Carton, Plastic Film ) (Potato, Palm Oil)

2a 2b
Packing Storage Ambient Storage
(Carton, Plastik Film) (Potato, Palm Oil)

3 Low Risk Area


Low Risk Area Washing

4
Peeling

5
Slicing

6
Blanching

7
Palm Oil Frying

8
Optic Sorter
Waste
9
Packing
10
Metal Detector
Rework Waste
11
Potato Chips

Low Risk Area Low Risk Area


12 Distribution
Note : : CCP

Approved By : Checked By :

PT. MRT
(Plant Manager) (Food Safety Team Leader)
Date : Date :
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Layout Potato Revision Rev 2
Chip Effective Date 01 Januari 2020
Page 2 of 18

7 6 5 4 3 2

10 9 13
14

17
24
18
25
15
19
11

20
16
12
21

22 23

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Layout Potato Revision Rev 2
Chip Effective Date 01 Januari 2020
Page 3 of 18

Layout Information :

: Finish Good Out


: Packaging Material In
: Raw Material In
: Pedestrian
: Low Risk Area

1. Office
2. Extrance Employee
3. Entrance Employee
4. Toilet
5. Changing Room
6. Changging Room
7. Toilet
8. Unloading Area
9. Packaging Storage
10. Raw Material Storage
11. Laboratory
12. Rework Area
13. Palm Oil Storage
14. Workshop Maintenance
15. Genset
16. Water Treatment
17. Washing and Peeling Area
18. Slicing Area
19. Blanching Area
20. Frying and Optic Sorter
21. Packing Area and Metal Detector Area
22. Hazardous Waste
23. Waste Water Treatment
24. Finish Good Warehouse
25. Loading Area
Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :
PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Product Description Revision Rev 2
Potato Chips Effective Date 01 Januari 2020
Page 4 of 18

1.0 PRODUCT DESCRIPTION


This product is made from real potatoes which are fried using oil to get crispy product
characteristics
2.0 INGREDIENT MATERIAL
Potatoes
3.0 PACKAGING
Packed in sachet plastic packaging as primary packaging with 100 gram packaging weight
and then packed in carton boxes (60pcs)
4.0 LABEL
4.1 Product Brand
4.2 Product Name
4.3 Company Logo and name
4.4 Halal logo and and certificate number
4.5 Distribution Permit
4.6 Front Of Pack
4.7 Ingredients
4.8 SNI
4.9 Production Date
4.10 Expired Date
4.11 Recycle Logo
4.12 Nett Weight
4.13 Manufacture Address
5.0 STORAGE METHOD
5.1 Stored in dry place and not expose to direct sunlight
5.2 Maximum buildup (10 stacks in 1 pallet)
6.0 USABILITY
This product can be consumed for toddlers
7.0 Shelf life
maximum 12 month from the date production
8.0 DISTRIBUTION
The process of distributing this product uses a closed vehicle

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Product Description Revision Rev 2
Potato Chips Effective Date 01 Januari 2020
Page 5 of 18

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :

PT. MRT
HACCP PLAN PT. MRT
Raw Material Document Number 1A/QA/HACCP/20
Revision Rev 2
Description Potato Effective Date 01 Januari 2020
Chip Page 6 of 18

1.0 RAW MATERIAL DESCRIPTION


1.1 Potatoes
Potatoes (Solanum tuberosum L.) are the result of agricultural commodities that
fall into tubers category
Origin : Indonesia

2.2 Palm Oil


Oil produced from oil palm fruit trees
Origin : Indonesia

2.0 INGRIDIENT OF RAW MATERIAL


( Can be seen in attached specification )
3.0 Packaging
3.1 Potatoes
Packed in sack with a weight of 50 kg
3.2 Palm Oil
Packed in large tank with capacity of 1000 L

PT. MRT
HACCP PLAN PT. MRT
Raw Material Document Number 1A/QA/HACCP/20
Revision Rev 2
Description Potato Effective Date 01 Januari 2020
Chip Page 7 of 18

4.0 LABEL
-
5.0 STORAGE METHODS
5.1 Potatoes
Stored in room temperature with light intensity not too high
5.2 Palm Oil
Stored in a clean storage tank and maintained at room temperature

6.0 USABILITY
6.1 Potatoes
The main raw material in the process of producing potato chips
6.2 Palm Oil
Supporting material in the process of frying potato chips
7.0 SHELF LIFE
7.1 Potatoes
2 Weeks After harvest

7.2 Palm Oil


A maximum of 6 months from the date of production
8.0 SUPPLIER
8.1 Potato
PT. Agro Fresh Bersemai
8.2 Palm Oil
PT. Minyak Kelapa Sejahtera

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Packaging Description Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 8 of 18

1.0 PACKAGING DESCRIPTION


1.1 Plastic Film
The primary packaging used is safe packaging when in direct contact with
food (food grade)

2.2 Carton
The secondary packaging used is made of cardboard material that is clean, not
wet and not torn with dimensions 25x 35 x 24

2.0 INGREDIENTS
( Can be seen in attached specification )

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Packaging Description Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 9 of 18

3.0 KEMASAN
3.1 Plastic Film
Packed with 4 cartons each
3.2 Carton
Packed by wrapping on a pallet with a total of 100 pcs / carton
4.0 LABEL
4.1 Plastic Film
- Product Name
- Company logo and name
4.2 Carton
- Product Name
- Company logo and name
5.0 STORAGE METHOD
5.1 Plastic Film
A maximum of 4 stacks / pallets
5.2 Carton
1 palette for 100 pc
6.0 SUPPLIER
6.1 Plastic Film
PT. Bumi Alam Package
6.2 Carton
PT. Dunia Kemasan Indonesia

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :
PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 10 of 18

Control Measure Selection Decision Tree


Code Step Process Potential Hazzard Likelihood Severity Significance
Category Control Measure Q1 Q2 Q3 Q4 CCP
Sampling every receiving
P Dust, hair 2 1 Low(2) PRP - - - -
PM
Receiving Packaging B N/I - - - - - - - - -
1a
Material Retur packaging and
C Ink 1 2 Low (2) PRP packaging series - - - -
documented
Washing Process (Step Not
P Soil 3 1 High (3) OPRP N
3b) CCP
Controlled CoA every Not
B Salmonella, E. Coli 2 3 High (6) OPRP Y Y N
Receiving Raw Receive RM CCP
1b
Material Pesticides
Residues, GMO, Controlled CoA every Not
C 2 3 High (9) OPRP Y Y N
Solanin, FFA, week and check (Step 9b) CCP
Rancidty
P N/I - - - - - - - - -
Controlled palet
2a Packaging Storage B Mould 1 2 Medium (2) - - - - -
condition
C N/I - - - - - - - - -
Washing treatment with
P Soil 2 1 Medium (2) - - - - -
water high preasure
Control of cleaning and Not
3 Washing B Salmonella, E. Coli 2 3 High (6) OPRP Y N Y Y
disinfection programs CCP
Not
C Solanin 2 3 High (6) OPRP Check Step 9b Y N Y Y
CCP
Hair, Metal Not
4 Peeling P 3 3 High (9) OPRP Control Foreign Materials Y N Y Y
Fragment CCP
Microba Patoghen Control of cleaning and Not
B 2 3 High (6) OPRP Y N Y Y
From equipment disinfection programs CCP

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 11 of 18

Residues of Control of cleaning and Not


C 2 3 High (6) OPRP Y N N
Cleaning Agent disinfection programs CCP
5 Slicing P N/I - - - - -
Control of cleaning and Not
B Salmonella, E. Coli 2 3 High (6) OPRP Y N N
disinfection programs CCP
Control of cleaning and
C Lubricants 2 2 Medium (4) PRP
disinfection programs
6 Blanching P N/I - - - - -
Not
B Salmonella, E. Coli 2 3 High (6) Check Step 7b Y N Y Y
CCP
Residues of Control of cleaning and Not
C 2 3 High (6) OPRP Y N N
Cleaning Agent disinfection programs CCP
7 Frying P Hair, Dust 2 2 Medium (4) PRP Control Foreign Materials
Setting Temperature
B Salmonella, E. Coli 2 3 High (6) CCP Y N Y N CCP1
Fryer
Control of cleaning and
C FFA, Rancidity 1 3 Low (3) PRP
disinfection programs
Check the metal detector
Not
8 Optical Sorter P Metal Fragment 2 3 High (6) OPRP at the beginning of each Y N N
CCP
shift
B N/I - - - - -
Verify equipment at the
C Solanin 2 3 High (6) CCP Y Y CCP2
beginning of production
Hair, Part of Use Hair Net and
9 Packing P 1 2 Low (2) PRP
Packaging controlled packaging
B NA - - - -
Control PM before use Not
C Ink 1 3 Low (3) PRP
and control COA CCP

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 12 of 18

Verify metal detector at


10 Metal Detector P Metal Fragment 2 3 Hard (6) CCP the beginning of Y Y CCP3
production
B N/I - - - - -
C N/I - - - - -
11 Finish Good P N/I - - - -
B N/I - - - -
C N/I - - - -
12 Distribution P N/I - - - -
B N/I - - - -
C N/I - - - -
Ref : - Internal Audit
- Record
- BPOM

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 13 of 18

To decide the significance of hazard, please see chart below :

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 14 of 18

To decide the significance of hazard from Raw Mateial, please see chart below :
Decision Tree

PT. MRT
HACCP PLAN PT. MRT
Document Number 1A/QA/HACCP/20
Hazzard Analysis Revision Rev 2
Potato Chip Effective Date 01 Januari 2020
Page 15 of 18

To decide the significance of hazard for process, please see chart below :
Decision Tree

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :

PT. MRT
HACCP PLAN PT. MRT
HACCP System Document Number 1A/QA/HACCP/20
Revision Rev 2
Verification Schedule Effective Date 01 Januari 2020
Potato Chip Page 16 of 18

CCP Hazzard Control Critical Limit Monitoring Corrective / Preventive responsibility and Documentatio Verification Validation
Control Action authority n
CCP1 E.Coli, Check T : 165 OC – What : - Reset the time and Checked By : From checking Daily form Lab Test
Salmonella Setting 185OC and Checking temperature of the Qc Inline the checking
from raw Time and Time 3 – 5 product from fryer Processing temperature by the Thermom
material and Temperatu Min) fryer - Quarantine the and time of head of ether
equipment re Fryer Where : product in the batch Corrective/Preventi the frying pan production calibration
every 2 Fryer - Make sure the fryer ve Action : certificate
hour When : temperature is up to Operator fryer, Check form
Every 2 hour standard before head production weekly by
Who : production begins and Maintenance the Food
QC inline - Thermometer Head Safety
Processing Calibration Fryer Team
How : periodically (6 months) Verify : Food Safety Leader
Team Leader
CCP2 Solanin Optical Solanin : N/I What : - Stop the production Checked By : From optical Daily form Calibrate
sorter Checking a - Make improvements Operator Optical sorter checking optical
checking at test sample to the optical sorter Sorter inspection by the sorter
the Where : - Hold The product head of every year
beginning Optical Sorter - Re-sorting the batch Corrective/Preventi production
every shift When : Every indicated to contain ve Action :
by using a Shift Change solanine Operator Optical Check form
test sample Who : Sorter, head weekly by
Operator production and the Food
Optical Sorter Maintenance Head Safety
How : Pass the Team
test sample to Verify : Food Safety Leader
the Optical Team Leader
Sorter.

PT. MRT
HACCP PLAN PT. MRT
HACCP System Document Number 1A/QA/HACCP/20
Revision Rev 2
Verification Schedule Effective Date 01 Januari 2020
Potato Chip Page 17 of 18

CCP 3 Metal Check the Metal Fragment What : - Stop the production Checked By : From the Daily form Metal
Fragment metal : N/I checking - Make improvements Operator Optical Metal checking detector
detector at metal to the metal detector Sorter Detector by the calibration
the detector test - Hold The product inspection head of every year
beginning samples - Re-sorting the batch Corrective/Preventi production
of each Where : Metal indicated to contain ve Action :
shift by Detector metal fragment Operator Metal Check form
using a test When : Every Detector, head weekly by
sample Shift Change production and the Food
Who : Maintenance Head Safety
Operator Team
Metal Verify : Food Safety Leader
Detector Team Leader
How : Pass the
test sample to
the metal
detector.

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :

PT. MRT
HACCP PLAN PT. MRT
HACCP System Document Number 1A/QA/HACCP/20
Revision Rev 2
Verification Schedule Effective Date 01 Januari 2020
Potato Chip Page 18 of 18

Responsibility
Planned Verification Activity Time Interval Responsibility for Review
for Action
Establish verification inspection schedule Annually HACCP team QA Manager
Review of HACCP plan and its implementation Annually, or whenever a change to product HACCP team QA Manager
or process
Validation of Critical Limit Initially, or whenever a change to product HACCP team QA Manager
or process
Presence and correctness of CCP Monitoring As per HACCP plan As per HACCP As per HACCP plan
plan
Monitoring equipment calibrated/operating 6 monthly External Engineering manager
calibration
Review monitoring and corrective action record Monthly Production Plan manager
manager
Sample analysis to verify CCP is under control Annually QA technical QA manager
Presence written verification report Annually HACCP team QA manager
Preventive maintenance As per schedule Fitters Engineering manager

Approved By : Checked By :

(Plant Manager) (Food Safety Team Leader)


Date : Date :

PT. MRT