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Doc No: UZ-P02-F01

Issue No: 1
UZ FOOD BERHAD
Issue Date: 01/06/2019
HACCP PLAN
Page: 1 of 5

Product Description & Intended Use

1 Product Name Andy’s Ice Cream Cup Cake

2 Composition Muffin, whip cream, ice cream and filling of toppings


3 Flavours Triple chocolate chip, vanilla chocolate chip, mocha almond fudge, cookies & cream,
fruity strawberry and killer blueberry
4 Important Product Characteristic Free of pathogenic microorganism
Relevant To Food Safety Biology - E. coli, Coliform, S.aureus, Salmonella
(Biological, Chemical, Physical) Chemical – No residue from cleaning chemical, no preservatives.
Physical - Free from visible foreign material that is more than 2 mm in diameter
5 Process Type/ Treatment Receiving, storage, decartoning, weighing, filling, packaging, cartooning, finished good
storage, demurrage

6 Intended Shelf-life 12 months from the date of manufacture if kept at freezing storage temperature of
-18ºC and below
7 Storage Condition Keep refrigerated at storage freezing temperature of -18ºC and below
8 Packaging System Primary and secondary packaging
9 Packing size Individually wrapped
10 Labeling Information for Consumer/ Keep frozen less than -18°C, expiry date
User
11 Distribution Condition & Method Freezer truck @ -18 to -25°C
12 Traceability Code Product name, batch no/lot no, best before
13 Where the Products will be sold Supermarket/ Hotel
14 Intended Use Ready-to-eat
15 Intended Consumer/ User General public consumption
16 Mishandling possibility Cold chain management & temperature control
Doc No: UZ-P02-F01

Issue No: 1
UZ FOOD BERHAD
Issue Date: 01/06/2019
HACCP PLAN
Page: 2 of 5

Hazard Analysis for Worksheet for Raw material


* refer food safety matrix below to determine significance of hazard
** refer decision tree below for raw mat/ process

Raw/ Potential Hazard Rationale for inclusion or Preventive Measure or Controls Is this a Sensitive Raw/ Packaging
Significance of Hazard
Packaging (B: Biological, C: exclusion as a Hazard applied to prevent this significant Material?
Material Chemical, P: Physical) (In: Inclusion, Ex:Exclusion) Sev Like Y/N hazard Q1 Q2 Q3 Y/N
Muffin B: Presence of Ex :Proper temperature 2 D 12 No  Microbe test on yearly basis N - - N
(Finished microbial control
Product) contamination
C : Nil n/a - - - - N - - N

P: Foreign materials In : Improper processing 4 C 18 No  N/A N - - N


such as dust, rope or control by supplier
thread
Whipping B: Presence of Ex :Proper temperature 2 D 12 No - N - - N
Cream microbial control
contamination
C : Nil n/a - - - - N - - N

P : Foreign materials n/a - - - - N - - N


e.g. rope or thread

Ice Cream B: Presence of Ex :Proper temperature 2 D 12 No  Microbe test on yearly basis N - - N


(Flavours) microbial control
Finished contamination
Product C: Allergen In : Dairy can cause allergenic 2 D 12 No  Labelling of products N - - N
reaction to sensitive individual  Allergen declaration

P: Foreign materials In : Improper processing 4 D 21 No  N/A N - - N


such as dust, rope or control by supplier
thread
B: Presence of Ex :Proper temperature 2 D 12 No - N - - N
Toppings microbial control
(Flavours) contamination
C : Nil n/a - - - - N - - N
P : Foreign materials In :Improper processing control - - - - N - - N
e.g. rope or thread by supplier

Hazard Analysis Worksheet for Process Step

Potential Hazard Rationale for inclusion or Significance of Hazard Preventive Measure or Controls Is this a Critical Control Point (CCP)?
Process Step (B: Biological, C: exclusion as a Hazard applied to prevent this significant
Chemical, P: Physical) (In: Inclusion, Ex: Exclusion) Sev Like Y/N hazard Q1 Q2 Q3 Q4 Y/N
Receiving & B: Microbial Ex: Proper building setting, 2 C 8  Incoming/outgoing records Y Y - - Y
Storage contamination e.g. proper storage condition setting  Temperature monitoring 3 CCP 1
Yes
E.coli, Coliform, times a day
S.aureus  Worker practices good
hygiene and GMP program
in place to prevent
contamination
C : Nil n/a - - - - N - - - N

P : Foreign materials In: Improper handling or 4 C 18  Maintain clean environment N - - - N


e.g. rope or thread contaminated environment/ No  Train workers on proper food
equipment handling practices

Weighing B: Microbial In: Improper handling or 2 D 12  Maintain clean environment N - - - N


contamination e.g. contaminated environment/ No  Train workers on proper food
E.coli, Coliform, equipment handling practices
S.aureus
C : Nil n/a - - - - N - - - N

P: Foreign materials In: Improper handling or 4 C 18  Maintain clean environment N - - - N


e.g. rope or thread contaminated environment/ No  Train workers on proper food
equipment handling practices

Filling/ B: Presence of Ex: Proper temperature control 2 D 12 - N - - - N


Decorating microbial contamination No
Doc No: UZ-P02-F01

Issue No: 1
UZ FOOD BERHAD
Issue Date: 01/06/2019
HACCP PLAN
Page: 3 of 5

C : Nil n/a - - - - N - - - N

P : Foreign materials n/a - - - - N - - - N


e.g. rope or thread

Traying Microbial contamination Ex: Proper temperature control 2 D 12 - N - - - N


(Trolley e.g. E.coli, Coliform, No
based) S.aureus
C : Nil n/a - - - - N - - - N

P : Foreign materials In: Improper handling or 4 C 18  Washing trays at end of N - - - N


e.g. rope or thread contaminated environment / No production
equipment  Train workers on proper food
handling practices

Packaging Microbial contamination Ex: Proper temperature control 2 D 12 - N - - - N


e.g. E.coli, Coliform, No
S.aureus
C : Nil n/a - - - - N - - - N

P : n/a n/a - - -  Maintain clean environment N - - - N


 Train workers on proper food
handling practices

Cartoning Microbial contamination Ex: Proper temperature control 2 D 12  Monitor on room temperature N - - - N
e.g. E.coli, Coliform, No
S.aureus
C : Nil n/a - - - - N - - - N

P : n/a n/a - - - - N - - - N

Freezing Microbial contamination In : Temperature multifunction 2 C 8  Temperature monitoring on a Y Y - - Y


e.g. E.coli, Coliform, due to break down daily basis 3 times a day CCP 2
Yes
S.aureus
C : Nil n/a - - - - - - - - -

P : n/a n/a - - - - - - - - -

Food safety matrix

Likelihood
Severity
A B C D E Severity (Consequence) Likelihood (Frequency)
1 1 2 4 7 11 1. Can be fatal A. Common occurrence
2 3 5 8 12 16 2. Can cause serious illness B. Known to occur or “it has happened at our premise”
3 6 9 13 17 20 3. Can result in a product recall C. Could occur or “I’ve heard of it happening” (published information)
4 10 14 18 21 23 4. Can generate customer complaint D. Not expected to occur
5 15 19 22 24 25 5. Insignificant E. Practically impossible
1 to 10: Essential to have control measures in place to reduce food safety hazards.
11 to 25: Up to the Food Safety Team to decide whether it makes good business sense to have control measures in place to reduce the food safety hazards.
Doc No: UZ-P02-F01

Issue No: 1
UZ FOOD BERHAD
Issue Date: 01/06/2019
HACCP PLAN
Page: 4 of 5

Raw Material/ Packaging Material Decision Tree

Q1: Is there a hazard with this raw material/ packaging material?

No Not a sensitive raw material/ Go to next raw material/


Yes
packaging material packaging material

Q2: Are you or the consumer going to process this hazard out of the product?

No Sensitive raw material /


Yes
packaging material

Q3: Is there a cross-contamination risk to the facility or to other products which


will not be controlled?

Yes No Not a sensitive raw material/ Go to next raw material/


packaging material packaging material
Sensitive raw material /
packaging material

Source: MS1480:2007 Food Safety According to Hazard Analysis Critical Control Point (HACCP) System

Process Step Decision Tree


Modify process step,
Q1: Are there control measure(s) for the significant hazard? process or product
Yes
No
Yes Is control at this process step No Stop. Proceed to
necessary for product safety? Not a CCP
next Process step

Q2: Is the process step specifically designed to eliminate or reduce the Yes
likely occurrence of a hazard to an acceptable level?

No

Q3: Could contamination occur at unacceptable level(s) or increase to


unacceptable level(s)?

Yes Stop. Proceed to


No Not a CCP
next Process step

Q4: Will a subsequent process step eliminate or reduce the significant CRITICAL
hazard to an acceptable level? CONTROL POINT

Yes
Stop. Proceed to
Not a CCP
next Process step

Source: MS1480:2007 Food Safety According to Hazard Analysis Critical Control Point (HACCP) System
Doc No: UZ-P02-F01

Issue No: 1
UZ FOOD BERHAD
Issue Date: 01/06/2019
HACCP PLAN
Page: 5 of 5

HACCP Plan Summary

CCP No. Significant Critical Limits Monitoring Correction & Verification Records
Hazard(s) What How When Who Corrective Action (What, How, When,
Who)
CCP 1 Microbial Receive raw Raw materials Check and Upon Storeke  Reject any raw  Daily monitoring  Receiving Record
Receiving survival materials from record the receipt eper materials that by Storekeeper
e.g. mold, the Approved receiving of each are not from the on Receiving
Salmonella Supplier List date shipme Approved Records
, Bacillus nt Supplier List
cereus or
presence
of foreign
materials
e.g. Follow receiving Raw materials Check and Upon Storeke  Reject any raw  Daily monitoring  Receiving Record
rope or criteria record the receipt eper materials that by storekeeper on
thread receiving of each does not follow Receiving
date shipme the receiving Records
nt criteria
Temperature Temperature Check and Each QC  QC shall monitor  Daily monitoring  Receiving Record
(≤ -18o C) record the batch the temperature by QA/QC on
temperatu the received Receiving  External
re of goods Records Calibration Record
goods  Reject raw UZ-P5-F02
materials which  Calibration on
are below the thermometer
temperature limit
(≤-15 o C)

CCP 2 Microbial Freezer Temperature Check and 3 times Kitchen  Kitchen Leader  Daily monitoring  Freezer
Freezing survival Temperature record on a day Leader to monitor the by Kitchen Leader Temperature
(Storage) e.g. mold, (≤-18oC) temperatu temperature on Temperature Record
Salmonella re display control, inform Records UZ-P2-F01a
, Bacillus maintenance if
cereus any breakdown.  Calibration on  External Calibration
temperature Record
sensor UZ-P5-F02

 QA to send  External
finished products microbiological
for external lab results
test on a yearly
basis

HACCP VERIFICATION PLAN

No Activity Frequency Responsibility Records

1 Receiving (Receiving Temperature) Each batch QC Receiving Record

2 Storage (Freezer Temperature) 3 times a day Kitchen Leader Freezer Record


UZ-P2-F01a
3 Thermometer Calibration (External) Yearly QA/ QC Calibration Record/ Certificate

4 Microbiology testing of Finished Goods Yearly QA/ QC Microbe Test Report


(External)