R&w wholesale 2015 haccp plan book

Page 1

Preparation of Fresh Meat HACCP Plan HACCP people

Business Name: Ruby & White

Team Leader:

Business Address: Unit 5B, Kingsland Trading Estate, St Phillips, Bristol, BS2 0JZ

Role in company

Team Member 1:

Dave Kelly Manager

Craig Parker Wholesale Manager

Role in company HACCP Study For (Process or Procedure): preparation of fresh meat Date of Preparation: 19 / 07 / 2014 (D/M/Y) Revised & Updated : 11/ 12 / 2014 (D/M/Y)

Team Member 2: Role in company

Nick Iles Transport team leader

Team Member 3:

Krystian Kobus

Role in company

Wholesale Production Manager

PROCESS STEPS HACCP PLAN FOR: Preparation of Fresh Meat This HACCP plan was prepared by: Dave Kelly

Step 1 Purchase, delivery and receipt of fresh meats

Date of preparation19/07/2014 / Updated & Revised 11/12/2014 Step 2 Storage in fresh meat chiller 1)

Scope of Study: Biological Safety: The main aim of this HACCP study is to prevent, eliminate or reduce the microbiological contamination of food and to reduce the potential for growth.

Step 3 Debone & Prepare for retail sale or further processing.

2) Physical and Chemical Safety: To avoid the introduction of physical and chemical contaminants onto any food. Step 4 Vacuum packing of fresh meat cuts Details of Process: This HACCP plan covers 1) The purchase and delivery of red meat i.e beef, pork & lamb, and white poultry meats from reputable suppliers in the form of carcasses, quarters, primals or cuts. 2) The storage of raw meats under appropriate refrigeration conditions and preparation for sale within the Butchery Room at controlled temperatures. The prepared raw meat is then available for direct sale to retail & wholesale customers.

Step 5 Storage of prepared meats in Chiller

Step 6 Delivery to wholesale customers. Details of storage: Raw meat is stored in the raw meat chiller prior to preparation. Prepared cuts, diced and sliced raw meats and minced raw meats are held at chilled temperatures prior to sale and delivery. Prepared cuts are also vacuum packed when required, and sold with a shelf-life no greater than 10 days from preparation.

Details of use and customer: Raw meat cuts and preparations are sold directly to retail customers or delivered to wholesale customers including local restaurants and hotels.

PROCESS STEP: 1. Purchase, delivery and receipt of fresh meats

FOOD SAFETY HAZARD AND CAUSE Break in the Cold Chain causing meat products to fall outside of safe temperature ranges Growth of food poisoning bacteria (eg E Coli 57) and spoilage within meats prior to delivery. Cross contamination by physical/ chemical contaminants prior to delivery.

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

All meats purchased from selected and approved EC licensed suppliers. Delivered by clean, refrigerated vehicles. Delivery temp at <3 for Offal, <4 Poultry and <7 Other Meats Minimise transfer time from delivery vehicle to raw meats chill storage. (Less than 10 minutes) Staff training. Staff hygiene rules including hand washing and adhering to company hygiene policy.

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

CRITICAL LIMITS

MONITORING Procedure

Frequency

Responsibility

Q1: JUSTIFICATION

YES Or NO

Bacterial contamination could occur prior to delivery. The delivery process itself occurs at ambient temperature, but the time taken is short and there is very low risk of bacterial growth. Bacterial transfer can occur however, from the delivery vehicle

Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination. NO This step IS a CCP.

CORRECTIVE ACTIONS Records

Procedure

Responsibility

Records

Dave Kelly YES

Selection of EC approved meat suppliers No unpleasant, noxious odours indicating spoilage. Delivery at or <3 for Offal, <4 Poultry and <7 Other Meats

Supplier selection process.

Each supplier

Assessment of incoming meat deliveries

Every delivery

FM02

Reject delivery if delivery does not meet criteria. Review supplier approval

Check internal meat temperature on delivery & prior to use with calibrated, disinfected thermometer probe.

Two samples per delivery

FM02

INFORM FSA & LOCAL AUTHORITY

Dave Kelly

Butchery Diary Notes

PROCESS STEP: 2. Storage in fresh meat chiller FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in Butchery Chill.

Chill storage <3C

Contamination by bacteria from poor staff hygiene.

Staff training. Staff hygiene rules and company hygiene policy must be followed.

Cross contamination by bacterial/physical/ chemical contaminants from within Butchery Chill.

Correct rotation (FIFO)

Correct cleaning and maintenance of Chill as stated in company cleaning and maintenance schedules. Stock to be kept off ground level on designated shelving units / hooks.

Refrigerated storage will not reduce bacterial contamination of the product, it will only slow growth of bacteria present. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP? YES

CRITICAL LIMITS

Product storage at <3 degrees Strict first in, first out stock control system Staff hygiene rules& cleaning schedule followed

MONITORING Procedure

Frequency

Visual check of fridge temperature using digital display. Check meat temp with calibrated, sanitised probe thermometer.

Twice daily Start & end of work period.

Check stock rotation. All meats labelled with origin & date of receipt

Daily at start of work period

Check use of designated workwear and hand-washing procedures. Visual Check.

Daily

Check cleaning schedule for kitchen followed correctly. Visual check Daily

Responsibility Krystian Kobus Craig Parker

Q1: JUSTIFICATION

YES Or NO

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination.

Q3: JUSTIFICATION There is no further process under our control that will reduce contamination to an acceptable level. NO This step IS a CCP.

CORRECTIVE ACTIONS Records

Procedure

FM02 GOODS IN

Destroy suspect meats Adjust/repair fridge and check temperature.

FM03 TEMPERATU RE CHECK

Destroy suspect meats Retrain staff, review rotation policy.

FM03

Re-clean, review cleaning procedure.

Training matrix

FM05C/a CLEANING CHECK

Inform FSA if necessary.

Responsibility

Records

Dave Kelly Butchery Diary Notes

PROCESS STEP: 3. Debone & Prepare for sale or further processing.

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at ambient temperature in Butchery

Minimise time held at controlled ambient temperature in cutting room <8-10 degrees. Required meat cuts prepared in < 60 mins. Progressive workflow adopted.

Contamination of meat by bacteria from unclean contact surfaces/equipment.

Strict good hygiene butchery practices maintained at all times including hand-wash procedures. Correct cleaning and maintenance of equipment as stated in company cleaning and maintenance schedules.

Contamination by bacteria from poor staff hygiene.

Staff training. Staff hygiene rules and company hygiene policy must be followed.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

CRITICAL LIMITS

MONITORING Procedure

Frequency

Responsibility

Q1: JUSTIFICATION

YES Or NO

There is a significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices.

Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination. NO This step IS a CCP.

CORRECTIVE ACTIONS Records

Procedure

Responsibility

Records

D.K

YES

Swift movement of meats through processing Staff hygiene rules followed

Cleaning schedule followed

Continual monitoring as meat moves through butchery Check use of designated workwear and hand-washing procedures. Visual Check Check cleaning schedule for Butchery followed correctly. Visual check with a sign off by manager.

Movement of each batch recorded.

K.K / C.P FM03 TEMPERATU RE CHECK FM05C/a CLEANING CHECK

Destroy suspect product Review butchery procedures

Butchery Diary Notes Training matrix

Destroy suspect product Retrain staff Re-clean, retrain staff, review cleaning procedure

PROCESS STEP: 5. Storage of prepared meats in chiller FOOD SAFETY HAZARD AND CAUSE Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in Butchery Chill. Contamination by bacteria from poor staff hygiene.

Cross contamination by bacterial/physical/ chemical contaminants from within Butchery Chill.

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Chill Storage: <3c Product made to order, so reducing amount having to be stored as surplus. Correct rotation (FIFO). Maximum storage for meat preparation 24hrs. Staff training. Staff hygiene rules and company hygiene policy must be followed including hand-wash procedures. Correct cleaning and maintenance of Chill as stated in company cleaning and maintenance schedules.

Refrigerated storage will not reduce bacterial contamination of the product, it will only slow growth of bacteria present. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

CRITICAL LIMITS

MONITORING Procedure

Frequency

Responsibility

Product storage at <3

YES

Product made to order, send out same day when possible. Marked with our EC ID number

Visual check of fridge temperature. Check meat temp with calibrated, sanitised probe thermometer. Check stock rotation

Twice daily Start & end of work period. Daily at start of work period

Strict first in, first out stock control system Staff hygiene rules & cleaning schedule followed

Check use of designated workwear and hand-washing procedures. Visual Check.

Daily

Check cleaning schedule for kitchen followed correctly. Visual check Daily

Krystian Kobus / Craig Parker

Q1: JUSTIFICATION

YES Or NO

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination.

Q3: JUSTIFICATION There is no further process under our control that will reduce contamination to an acceptable level. NO This step IS a CCP.

CORRECTIVE ACTIONS Records

Procedure

FM03 TEMPERATU RE CHECK

Destroy suspect meat preparations Adjust/repair fridge and check temperature.

FM05C/a CLEANING CHECK

Destroy suspect meat preparations Retrain staff, review rotation policy. Retrain staff

FM02 - Batch number info

Retrain staff, review rotation policy. Retrain staff

Stock take Excel sheet.

Re-clean, retrain staff, review cleaning procedure.

Responsibility Butchery Mngr

Records Butchery diary notes Training matrix

PROCESS STEP: 6. Delivery to wholesale customers.

FOOD SAFETY HAZARD AND CAUSE Growth of food-poisoning & spoilage in meats prior to delivery due to falling outside the safe temperature ranges. Cross contamination by bacterial/ physical/chemical processing equipment and food contact surfaces

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Delivery within clean vehicles, refrigerated. Delivery vehicles maintained regularly for refrigerator function by approved dealer + also manually monitored regularly by cross-checking with manual temperature check.

Minimise transfer time from delivery vehicle to customer chills <10 mins Ensure regular maintenance checks for vans to take place daily and are recorded. Correct cleaning and maintenance of equipment as mentioned in company policy.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

YES

CRITICAL LIMITS Delivery below <7 degrees for meats / <3 Offal, <4 poultry All meats delivered with packaging in sound condition, correctly labelled with our EC ID mark and dated.

MONITORING Procedure Delivery vehicle automatic temperature monitoring. Temps recorded at start and end of delivery. Meats signed for by customer upon delivery.

NO

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP?

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly.

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Deliveries to be below <7 degrees for meats / <3 Offal, <4 poultry

Frequency

Every delivery Every delivery

Responsibility

Individual driver / reporting to Nick Iles

Q1: JUSTIFICATION

YES Or NO

Bacterial numbers are unlikely to increase during transportation due to short distances and refrigerated conditions. Bacterial transfer can occur however, from the delivery vehicle and numbers may increase if transfer times from vehicle to customers’ chills are extended.

Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination. NO This step IS a CCP.

CORRECTIVE ACTIONS Records

Procedure

VA03

Abort delivery and return to shop

kooltech RECORDS

inform FSA if nec.

Responsibility

Nick Iles

Records

Delivery Diary Notes VM03

HACCP VALIDATION RECORD A validation check should be carried out BEFORE THE PLAN IS FIRST IMPLEMENTED or used to make sure it is thorough and accurate. If the Plan is in any way incomplete or inaccurate it MUST BE AMENDED before you use it. Yes Is the scope an accurate description of the process? Are flow charts identifying each step in the process? Are all significant hazards addressed? Are control measures in place? Are CCPs justified? Are critical limits acceptable? Are there procedures for monitoring? Are corrective actions in place and understood by relevant staff? Are there adequate records? Are all relevant hazards addressed? Does the plan control all hazards if followed correctly?

 

VALIDATION RECORD

Validation Carried Out By:

Position:

Signed:

Date Of Validation:

No

SHEET NO: HACCP VERIFICATION RECORD DATE

TYPE OF DOCUMENTATION OR WORKING PROCEDURE CHECKED

CORRECTIVE ACTION REQUIRED

CORRECTIVE ACTION CARRIED OUT BY

SIGNED

HACCP REVIEW Does the scope accurately describe the process?

If No – amend Plan.

Does the process stage correspond to the flow diagram?

If No – amend Plan.

Are controls valid for each hazard – Microbiological, Chemical and Physical?

If No – amend Plan.

Do the CCPs remain the same?

If No – amend Plan.

Are critical limits adequate?

If No – amend Plan.

Are monitoring procedures still effective for each CCP?

If No – amend Plan.

Are appropriate corrective actions identified?

If No – amend Plan.

REVIEW RECORD Review Carried Out By:

Position:

Signed:

Date Of Review:

AMENDMENT REQUIRED: Yes or No (If Yes, amend Plan then carry out validation)

Date Of Next Review:

Ruby & White HACCP Proposal Plan Cooked/Cured Meat Handling Procedure. HACCP people

Business Name: Ruby & White Business Address: Unit B5, Kingsland Trading Estate St Phillips, Bristol BS8 2NH

HACCP Study For (Process or Procedure): Cooked/Cured Meats

Date of Preparation: 08/01/2015 (D/M/Y)

Team Leader:

Dave Kelly Butchery Manager

Role in company

Team Member 1:

Craig Parker Wholesale Manager

Role in company

Team Member 2: Role in company

Team Member 3: Role in company

Krystian Kobus Production Manager

Nick Iles Transport Manager

PROCESS STEPS HACCPDeli PLAN FOR: Cooked/Cured Meats through Step 1 Purchase, delivery & receipt of cooked meats

This HACCP plan was prepared by: Dave Kelly

Step 2 Storage in designated area of Box Chiller

Date of preparation: 08/01/2015 (D/M/Y/) Step 3 Delivery to wholesale customers 1)

Scope of Study: Biological Safety: The main aim of this HACCP study is to prevent, eliminate or reduce the microbiological contamination of food and to reduce the potential for growth.

Step 4

2) Physical and Chemical Safety: To avoid the introduction of physical and chemical contaminants onto any food. Step 5 Details of Process: This HACCP plan covers the delivery and storage of Cooked Meats (i.e Wiltshire Ham) and Cured Deli meats (i.e Salami) These are delivered Pre-Cooked and packaged with batch numbers and relevant EEC codes of the reputable suppliers. The product has been stored under appropriate refrigeration prior to delivery, and the cold chain is maintained throughout storage at the unit and subsequent delivery to wholesale clientele. Although the product is not opened, cut or processed at the wholesale unit, (significantly reducing the risk of cross contamination) it is still stored separately from raw products, and not removed from chill storage until required. Details of storage: Cooked meats are stored in a designated area of the boxed meats fridge (1st left corner) at the required temperature below 4ยบc sold within the dates indicated.

Details of use and customer: Cooked meats are ordered in accordance with customer requirement. These are not processed or sliced on site.

Step 6

Step 7

PROCESS STEP: 1. Purchase, receipt and delivery FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning bacteria (eg E.coli157) and spoilage bacteria within meats prior to delivery.

Minimise time held at room temperature. Products should be refrigerated immediately after delivery to maintain the cold chain.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Contamination by bacteria from poor staff hygiene.

Staff training. Staff hygiene rules and company hygiene policy must be followed. Including hand-wash procedures.

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Correct cleaning of equipment as stated in company cleaning schedule.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Cross contamination by physical/chemical contaminants from processing equipment.

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Q1: JUSTIFICATION

YES Or NO

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

Q2: JUSTIFICATION

NO

This process occurs at controlled temperature and the time taken is short and there is very low risk of bacterial growth. Bacterial transfer can occur but this will not increase overall levels. This step is NOT a CCP.

Q3: JUSTIFICATION n/a

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP? YES

CRITICAL LIMITS Sourced only from reputable EC approved suppliers. No unpleasant, foul or noxious odours. Delivery at/lower than 4 degrees

MONITORING Procedure Supplier selection process. Thorough checks and assessment of incoming stock. - Temperatures / physical state of product/ packaging/batch no / date

Frequency Each delivery

Responsibility Dave Kelly / Butchery Staff

CORRECTIVE ACTIONS Records FM02

Procedure Reject delivery if unsatisfied with goods.

Responsibility Dave Kelly

Records Butchery Diary Notes

Review Supplier Approval FM02 Contact FSA if required

PROCESS STEP: 2. Storage in designated area of chiller

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Chill storage at <3-4degrees.

Contamination by bacteria from poor staff hygiene.

Items not removed from chiller until required.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Correct rotation (FIFO)

Staff Training. Cross contamination by bacterial from poor staff hygiene. Cross contamination by bacterial/physical/ chemical contaminants from within butchery chill.

Staff Hygiene rules and company hygiene policy must be followed. Correct cleaning and maintenance of chill as stated in company cleaning and maintenance schedules. Visual checks to ensure packaging is intact / not damaged in anyway prior to entering chiller - product must not be exposed/uncovered.

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels? QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

YES Or NO

Q1: JUSTIFICATION Refrigerated storage will not reduce bacterial contamination of product, it will only slow growth of bacteria present.

YES

Q2: JUSTIFICATION Inadequate temperature controls, poor stock rotation and cross-contamination can all increase level of bacterial contamination.

Q3: JUSTIFICATION n/a

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP? YES

CRITICAL LIMITS Product Storage <4 degrees. Use within timeframe indicated on packaging. Strict FIFO system. Staff hygiene & training rules followed

MONITORING Procedure Visual checks of Fridge temperatures/ records. Check meat temps with calibrated, sanitised probe thermometer.

Frequency Throughout work period.

Responsibility D.K / C.P / K.K

CORRECTIVE ACTIONS Records FM03 - temp FM05a/c cleaning

Procedure Destroy any suspect meats. Adjust/ Repair fridges and check temperature.

Check use of designated workwear and hand-washing procedures.

Destroy Suspect meats. Retrain staff, review rotation policy.

Check cleaning schedule for kitchen is followed correctly. Visual checks.

Re-clean, re train staff, review cleaning procedure.

Visual checks of condition of packaging/ product.

Responsibility Dave Kelly

Records Training Matrix Butchery Diary Notes

PROCESS STEP: 3. Delivery To Wholesale Customers

FOOD SAFETY HAZARD AND CAUSE Growth of food poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill. Cross Contamination by Physical/Chemical Contaminants prior to delivery or during delivery

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE Delivery within clean, refrigerated vehicles. Delivery temp to be <7 degrees red meats / <4 poultry / <3 offal. Minimise transfer time from dispatch room to vehicle, and from vehicle to customer chills <10 mins. Meat cuts and preparations wrapped in food grade packaging. Cooked/cured meats to be kept in designated crate/area of van - not to be mixed with raw meat deliveries. Staff hygiene rules and company hygiene policy must be followed.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP? YES

CRITICAL LIMITS Delivery at or lower than 7 degrees (<4 poultry / <3 offal) All meats delivered with packaging in sound condition, correctly labelled and dated

MONITORING Procedure Delivery vehicle automaticc temperature monitoring. Temps records at start and end of journey. Meats signed for by customer upon delivery

Frequency Every delivery

Responsibility Individual driver, reporting to Nick Iles

Q1: JUSTIFICATION

YES Or NO

Bacterial numbers are unlikely to increase during transportation due to short distanced and refrigerated conditions. Bacterial transfer can occur however, from the delivery vehicle and numbers may increase if the transfer time from R&W Vehicle to customer chill is extended.

Q3: JUSTIFICATION

NO

This process is the last point of contact before consumption. There is no further process under our control that will reduce bacterial contamination. This step IS a CCP.

CORRECTIVE ACTIONS Records VM03

Procedure Abort delivery + return to Unit if any issues. Immediate repair of vehicle by trusted company

Responsibility Nick Iles

Records Maintenance log.

HACCP VALIDATION RECORD A validation check should be carried out BEFORE THE PLAN IS FIRST IMPLEMENTED or used to make sure it is thorough and accurate. If the Plan is in any way incomplete or inaccurate it MUST BE AMENDED before you use it. Yes Is the scope an accurate description of the process? Are flow charts identifying each step in the process? Are all significant hazards addressed? Are control measures in place? Are CCPs justified? Are critical limits acceptable? Are there procedures for monitoring? Are corrective actions in place and understood by relevant staff? Are there adequate records? Are all relevant hazards addressed? Does the plan control all hazards if followed correctly?

 

VALIDATION RECORD

Validation Carried Out By:

Position:

Signed:

Date Of Validation:

No

SHEET NO: HACCP VERIFICATION RECORD DATE

TYPE OF DOCUMENTATION OR WORKING PROCEDURE CHECKED

CORRECTIVE ACTION REQUIRED

CORRECTIVE ACTION CARRIED OUT BY

SIGNED

HACCP REVIEW YES Does the scope accurately describe the process?

If No – amend Plan.

Does the process stage correspond to the flow diagram?

If No – amend Plan.

Are controls valid for each hazard – Microbiological, Chemical and Physical?

If No – amend Plan.

Do the CCPs remain the same?

If No – amend Plan.

Are critical limits adequate?

If No – amend Plan.

Are monitoring procedures still effective for each CCP?

If No – amend Plan.

Are appropriate corrective actions identified?

If No – amend Plan.

NO

REVIEW RECORD Review Carried Out By:

Position:

Signed:

Date Of Review:

AMENDMENT REQUIRED: Yes or No (If Yes, amend Plan then carry out validation)

Date Of Next Review:

Ruby & White Wholesale HACCP Plan HACCP people

Business Name: Ruby & White Business Address: Unit 5B, Kingsland Trading Estate, St Phillips, Bristol, BS2 0JZ

Team Leader:

Dave Kelly

Role in company

Manager

HACCP Study For : Frozen meats/product procedure Original Date of Preparation: 19 / 07 / 2014 (D/M/Y) Revised & Updated : 11/ 12 / 2014 (D/M/Y)

Team Member 1: Role in company

Team Member 2:

Craig Parker Wholesale Butcher Manager

Krystian Kobus Wholesale Production Manager

Role in company

Team Member 3:

Nick Iles

Role in company

Transport team leader

PROCESS STEPS HACCPDeli PLAN FOR: Frozen Meats/Produce Procedure. through Step 1 Purchase, delivery & receipt of cooked meats

This HACCP plan was prepared by: Dave Kelly

Step 2 Storage in designated area of Box Chiller

Date of preparation: 08/01/2015 (D/M/Y/) Step 3 Delivery to wholesale customers 1)

Scope of Study: Biological Safety: The main aim of this HACCP study is to prevent, eliminate or reduce the microbiological contamination of food and to reduce the potential for growth.

Step 4

2) Physical and Chemical Safety: To avoid the introduction of physical and chemical contaminants onto any food. Step 5 Details of Process: This HACCP plan covers the delivery and storage of Frozen Meats. These are delivered Pre-Frozen and packaged with batch numbers and relevant EEC codes of the reputable suppliers. The product has been stored under appropriate temperatures prior to delivery, and the temperature is maintained throughout storage at the unit and subsequent delivery to wholesale clientele. Although the product is not opened, cut or processed at the wholesale unit, (significantly reducing the risk of cross contamination) it is still stored separately from raw products.

Details of storage: Packaged Meats are stored in a designated area of the Freezer at the required temperature -18 degrees and sold within the dates indicated.

Details of use and customer: Frozen meats are ordered in accordance with customer requirement. These are not defrosted, processed or sliced on site.

Step 6

Step 7

PROCESS STEP: 1. Purchase, receipt and delivery FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning bacteria (eg E.coli157) and spoilage bacteria within meats prior to delivery.

Minimise time held at room temperature. Products should be transferred to the Freezer immediately after delivery to maintain the cold chain.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Contamination by bacteria from poor staff hygiene.

Staff training. Staff hygiene rules and company hygiene policy must be followed. Including hand-wash procedures.

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Correct cleaning of equipment as stated in company cleaning schedule.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Cross contamination by physical/chemical contaminants from processing equipment.

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Q1: JUSTIFICATION

YES Or NO

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

Q2: JUSTIFICATION

NO

This process occurs at controlled temperature and the time taken is short and there is very low risk of bacterial growth. Bacterial transfer can occur but this will not increase overall levels. This step is NOT a CCP.

Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination.

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP? YES

CRITICAL LIMITS Sourced only from reputable EC approved suppliers. No unpleasant, foul or noxious odours. Delivery at/lower than -18 degrees Visual checks of product/packaging on arrival (no freezer burn/thawed patches on product)

MONITORING Procedure Supplier selection process. Thorough checks and assessment of incoming stock. - Temperatures / physical state of product/ packaging/batch no / date

Frequency Each delivery

Responsibility Dave Kelly / Butchery Staff

CORRECTIVE ACTIONS Records FM02

Procedure Reject delivery if unsatisfied with goods.

Responsibility Dave Kelly

Records Butchery Diary Notes

Review Supplier Approval FM02 Contact FSA if required

PROCESS STEP: 2. Storage in designated area of chiller

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Freezer Storage at -18 degrees.

Contamination by bacteria from poor staff hygiene.

Items not removed from Freezer until required.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Correct rotation (FIFO)

Staff Training. Cross contamination by bacterial from poor staff hygiene. Cross contamination by bacterial/physical/ chemical contaminants from within butchery chill.

Staff Hygiene rules and company hygiene policy must be followed. Correct cleaning and maintenance of chill as stated in company cleaning and maintenance schedules. Stored in designated areas of freezer.

Refrigerated storage will not reduce bacterial contamination of product, it will only slow growth of bacteria present NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels? QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Q1: JUSTIFICATION

YES Or NO

Q2: JUSTIFICATION

YES

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination.

Q3: JUSTIFICATION n/a

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP? YES

CRITICAL LIMITS Product Storage -18 degrees. Use within timeframe indicated on packaging. Strict FIFO system.

MONITORING Procedure Visual checks of Freezer temperatures/ records. Check meat temps with calibrated, sanitised probe laser thermometer.

Frequency Throughout work period.

Responsibility D.K / C.P / K.K

CORRECTIVE ACTIONS Records FM03 - temp FM05a/c cleaning

Procedure Destroy any suspect meats. Adjust/ Repair freezer and check temperature.

Check use of designated workwear and hand-washing procedures.

Destroy Suspect meats. Retrain staff, review rotation policy.

Check cleaning schedule for unit is followed correctly. Visual checks.

Re-clean, re train staff, review cleaning procedure.

Staff hygiene & training rules followed

Responsibility Dave Kelly

Records Training Matrix Butchery Diary Notes

PROCESS STEP: 3. Delivery To Wholesale Customers

FOOD SAFETY HAZARD AND CAUSE Growth of food poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill. Cross Contamination by Physical/Chemical Contaminants prior to delivery or during delivery

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE Delivery within clean, refrigerated vehicles. Delivery temp to be -18 degrees. Minimise transfer time from dispatch room to vehicle, and from vehicle to customer chills <10 mins. Meat cuts and preparations wrapped in food grade packaging + clearly labelled. Frozen meats to be kept in designated crate/area of van not to be mixed with raw/cooked meat deliveries. Staff hygiene rules and company hygiene policy must be followed.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly. NO

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP? YES

CRITICAL LIMITS Delivery at or lower than -18 All meats delivered with packaging in sound condition, correctly labelled and dated

MONITORING Procedure Delivery vehicle automatic temperature monitoring. Temps records at start and end of journey. Meats signed for by customer upon delivery

Frequency Every delivery

Responsibility Individual driver, reporting to Nick Iles

Q1: JUSTIFICATION

YES Or NO

Bacterial numbers are unlikely to increase during transportation due to short distances and frozen conditions. Bacterial Transfer can occur however, from the delivery vehicle and numbers many increase if transfer times from vehicle to customers’ chills are extended.

Q3: JUSTIFICATION

NO

This process is the last point of contact before consumption. There is no further process under our control that will reduce bacterial contamination. This step IS a CCP.

CORRECTIVE ACTIONS Records VM03

Procedure Abort delivery + return to Unit if any issues. Immediate repair of vehicle by trusted company

Responsibility Nick Iles

Records Maintenance log.

HACCP VALIDATION RECORD A validation check should be carried out BEFORE THE PLAN IS FIRST IMPLEMENTED or used to make sure it is thorough and accurate. If the Plan is in any way incomplete or inaccurate it MUST BE AMENDED before you use it. Yes Is the scope an accurate description of the process? Are flow charts identifying each step in the process? Are all significant hazards addressed? Are control measures in place? Are CCPs justified? Are critical limits acceptable? Are there procedures for monitoring? Are corrective actions in place and understood by relevant staff? Are there adequate records? Are all relevant hazards addressed? Does the plan control all hazards if followed correctly?

 

VALIDATION RECORD

Validation Carried Out By:

Position:

Signed:

Date Of Validation:

No

SHEET NO: HACCP VERIFICATION RECORD DATE

TYPE OF DOCUMENTATION OR WORKING PROCEDURE CHECKED

CORRECTIVE ACTION REQUIRED

CORRECTIVE ACTION CARRIED OUT BY

SIGNED

HACCP REVIEW YES Does the scope accurately describe the process?

If No – amend Plan.

Does the process stage correspond to the flow diagram?

If No – amend Plan.

Are controls valid for each hazard – Microbiological, Chemical and Physical?

If No – amend Plan.

Do the CCPs remain the same?

If No – amend Plan.

Are critical limits adequate?

If No – amend Plan.

Are monitoring procedures still effective for each CCP?

If No – amend Plan.

Are appropriate corrective actions identified?

If No – amend Plan.

NO

REVIEW RECORD Review Carried Out By:

Position:

Signed:

Date Of Review:

AMENDMENT REQUIRED: Yes or No (If Yes, amend Plan then carry out validation)

Date Of Next Review:

Ruby & White Wholesale HACCP Plan HACCP people

Business Name: Ruby & White Business Address: Unit 5B, Kingsland Trading Estate, St Phillips, Bristol, BS2 0JZ HACCP Study For (Process or Procedure): Minced Beef & Minced Beef Burgers Original Date of Preparation: 19 / 07 / 2014 (D/M/Y) Revised & Updated : 11/ 12 / 2014 (D/M/Y)

Team Leader:

Dave Kelly

Role in company

Manager

Team Member 1: Role in company

Team Member 2:

Craig Parker Wholesale Butcher Manager

Krystian Kobus Wholesale Production Manager

Role in company

Team Member 3:

Nick Iles

Role in company

Transport team leader

PROCESS STEPS HACCP PLAN FOR: Minced Beef & Minced Beef Burgers

Step 1: Purchase, delivery & receipt of fresh meat

This HACCP plan was prepared by: Dave Kelly Date of original preparation 19/07/2014 (D/M/Y/) Updated & Revised 11/12/2014 1)

Scope of Study: Biological Safety: The main aim of this HACCP study is to prevent, eliminate or reduce the microbiological contamination of food and to reduce the potential for growth.

Step 2 Storage in fresh meat chiller

Step 3 Debone & Prepare for retail sale or further processing

2) Physical and Chemical Safety: To avoid the introduction of physical and chemical contaminants onto any food.

Step 4 Meat cut into 5� Cubes

Details of Process:

Step 5 meat pushed through mincer for 1st cycle, then 2nd

This HACCP plan covers: 1) The manufacture and production of Minced Beef and Minced Beef burgers, from meat sourced and delivered by reputable supplier in the form of carcasses, quarters, primals or cuts. 2) The storage of raw meats under appropriate refrigeration conditions & preparation for sale within the Butchery Room at controlled temperatures. The prepared raw meat is then available for direct sale to wholesale customers.

Step 6 – 4th cycle, minced into clean tray

Step 7 Storage of prepared meat in chiller

Step 8 Beef burgers are created using a hand operated press

Step 9 Delivery to wholesale customers Details of storage: Raw meat is stored in the raw meat chiller prior to inspection. Prepared cuts, diced and sliced raw meats and minced raw meats are held at chilled temperatures prior to sale & delivery. Details of use and customer: Raw meat cuts are preparations are sold directly to retail customers or delivered to wholesale customers, including local restaurants and hotels, ensuring the cold chain is adhered to.

PROCESS STEP: Step 1 Purchase, delivery & receipt of fresh

CCP DETERMINATION

meat

FOOD SAFETY HAZARD AND CAUSE Break in the Cold Chain causing meat products to fall outside of safe temperature ranges

Growth of food poisoning bacteria (eg E Coli 57) and spoilage within meats prior to delivery.

Cross contamination by physical/ chemical contaminants prior to delivery.

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE All meats purchased from selected and approved EC licenced suppliers.

Does this process step prevent, No eliminate or reduce contamination to an acceptable level?

Delivered by clean, refrigerated vehicles. Delivery temp at <3 for Offal, <4 Poultry and <7 Other Meats

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Minimise transfer time from delivery vehicle to raw meats chill storage. Less than 10 minutes. Staff training. Staff hygiene rules including handwashing and company hygiene policy.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

YES

MONITORING

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly.

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP?

YES Or NO

Bacterial contamination could occur prior to delivery. The delivery process itself occurs at ambient temperature, but the time taken is short and there is very low risk of bacterial growth. Bacterial transfer can occur however, from the delivery vehicle. Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination.

no

This step IS a CCP

CORRECTIVE ACTIONS

CRITICAL LIMITS Procedure Selection of EC approved meat suppliers No unpleasant, noxious odours indicating spoilage. Delivery at or <3 for Offal, <4 Poultry and <7 Other Meats

Ensure Blue Stripe is present.

Supplier selection process. Assessment of incoming meat deliveries Check internal meat temperature on delivery & prior to use with calibrated, disinfected thermometer probe.

Frequency Each supplier Each delivery Two samples per delivery

Responsibility GOODS IN : Dave Kelly

Records

Procedure

FM02

Reject delivery

PRODUCT INTAKE FORM

Review supplier approval INFORM FSA & LOCAL AUTHORITY

Responsibility Dave Kelly

Records FM02 PRODUCT INTAKE FORM

PROCESS STEP: Step 2 Storage in Fresh meat chiller

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Chill storage <2c in designated chiller.

Contamination by bacteria from poor staff hygiene

Staff training Staff hygiene rules and company hygiene policy must be followed

Cross contamination by bacteria/physical/chemical contaminants from within butchery chill

Correct rotation (FIFO)

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Is this step a CCP? Yes

CRITICAL LIMITS

yes

Product storage at <2c in designated chiller. Used within time indicated by supplier packaging. Strict first in, first out stock control system Staff hygiene rules& cleaning schedule followed

Visual monitoring of fridge’s digital display. Check meat temp with calibrated thermometer (sanitised) Check stock rotation, all meats labelled and within date Check use of designated workwear and hand washing procedures. Visual checks Check cleaning schedule for kitchen followed correctly. Visual check

Frequency Twice daily start & end of work period Daily at start and end of work period Daily

Responsibility Krystian Kobus / Craig Parker

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP

MONITORING Procedure

Refrigerated storage will not reduce bacterial contamination of product, will only slow growth of bacteria present

Q2: JUSTIFICATION

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Q1: JUSTIFICATION

CORRECTIVE ACTIONS Records

Procedure

FM02 GOODS IN

Destroy suspect meats. Adjust/repair fridges.

FM03 TEMPERAT URE CHECK

Destroy suspect meats. Retrain staff, review rotation policy.

FM05C CLEANING CHECK

Reclean, retrain staff, review procedures Inform FSA

Responsibility Dave kelly

Records Butchery diary notes FSA log Training matrix

PROCESS STEP: Step 3 Debone & Prepare for retail sale or further

CCP DETERMINATION

processing

QUESTION 1 If YES This step is a CCP If NO Move on to next question

FOOD SAFETY HAZARD AND CAUSE

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at ambient temperature.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Small batches made to reduce amount of stock exposed to spoilage bacteria. Progressive workflow adopted.

Strict good hygiene butchery practices maintained at all times including hand-wash procedures. Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules FM05c / FM05a

Yes

CRITICAL LIMITS Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Check cleaning schedule for butchery followed correctly. Visual check

Frequency Movement of each batch recorded

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Minimise time held at controlled temperature. Required meat cuts prepared in <60 mins

Is this step a CCP?

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Responsibility

Records

Procedure

Krystian Kobus / Craig Parker

FM02 GOODS IN

Destroy suspect meats. Review processes

FM03 TEMPERAT URE CHECK

Destroy suspect meats. Retrain staff,

FM05C CLEANING CHECK

Reclean, retrain staff, review procedures

Responsibility Dave kelly

Records Butchery diary notes FSA log Training matrix

PROCESS STEP: Step 4 Meat cut into 5” Cubes, ready for mincing

CCP DETERMINATION

machine

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at ambient temperature, or being used after appropriate “mince by” date, as indicated on FM02 records.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Minimise time held at controlled temperature. Required meat cuts prepared in <60 mins

Small batches made to reduce amount of stock exposed to spoilage bacteria. Progressive workflow adopted.

Strict good hygiene butchery practices maintained at all times including hand-wash procedures. Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules FM05c / FM05a Strict FIFO policy on vacuum packed trim, packaging to be clearly labelled when stored.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Yes

CRITICAL LIMITS

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Check cleaning schedule for butchery followed correctly. Visual check

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

yes

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Frequency

Responsibility

Records

Movement of each batch recorded via Batch Numbers

Krystian Kobus / Craig Parker

FM03 TEMPERAT URE CHECK

Daily

Q1: JUSTIFICATION

Q2: JUSTIFICATION

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

YES Or NO

FM05C/a CLEANING CHECK FM02

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff, Reclean, retrain staff & review procedures

Responsibility Butchery mngr

Records Butchery diary notes Training matrix

PROCESS STEP: Step 5 meat pushed through mincer for 1st cycle, then

CCP DETERMINATION

2nd cycle

QUESTION 1 If YES This step is a CCP If NO Move on to next question

FOOD SAFETY HAZARD AND CAUSE

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees. Small batches made to reduce amount of stock exposed to spoilage bacteria. Progressive workflow adopted.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment Physical contaminants entering the mix through the mincer. Physical & chemical contaminants entering the mix through any seasoning mixtures, when used (rarely)

Minimise time held at controlled temperature. Required meat cuts prepared in <60 mins

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Ensure regular maintenance checks take place & parts are functioning correctly.

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Yes

CRITICAL LIMITS

MONITORING Procedure

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Check cleaning schedule for butchery equipment followed correctly. Visual check

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Ensure any spice/flavour mixes are securely stored away from chemical contaminants and perform visual checks prior to use.

Is this step a CCP?

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

Frequency Movement of each batch recorded Mincer condition checked daily.

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Responsibility

Records

Krystian Kobus / Craig Parker

FM03 TEMPERAT URE CHECK FM05C/a CLEANING CHECK

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff, Reclean, retrain staff, review procedures

Responsibility Butchery mngr

Records Butchery diary notes Training matrix Maintenance log

PROCESS STEP: Step 6 :3rd, then 4th cycle minced into clean tray &

CCP DETERMINATION

stored QUESTION 1 If YES This step is a CCP If NO Move on to next question

FOOD SAFETY HAZARD AND CAUSE

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees. Small batches made to reduce amount of stock exposed to spoilage bacteria. Progressive workflow adopted.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment Physical contaminants entering the mix through the mincer. Tray is not clean and/or damaged

Minimise time held at controlled temperature. Required meat cuts prepared in <60 mins

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Ensure regular maintenance checks take place & parts are functioning correctly.

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Yes

CRITICAL LIMITS

MONITORING Procedure

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed Check cleaning schedule for butchery followed correctly. Visual check

Frequency Movement of each batch recorded Daily

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Always use clean utensils/trays Is this step a CCP?

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Responsibility

Records

Krystian Kobus / Craig Parker

FM03 TEMPERAT URE CHECK FM05C/a CLEANING CHECK

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff, Reclean, retrain staff, review procedures

Responsibility Butchery mngr

Records Butchery diary notes Training matrix

PROCESS STEP: Step 7:Storage of prepared meat in chiller

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Chill Storage: <2c in designated chiller

Contamination by bacteria from poor staff hygiene

Correct rotation (FIFO)

Cross contamination by bacteria/ physical/chemical contaminants from within butchery chill

Staff training Staff hygiene rules and company hygiene policy must be followed

Product made to order, so reducing amount having to be stored as surplus.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Yes

Product storage at <2 degrees Product made to order, send out same day when possible. Marked with our EC ID number Strict first in, first out stock control system. Weekly stock take recorded Staff hygiene rules & cleaning schedule followed

MONITORING Procedure

Frequency

Q1: JUSTIFICATION

Refrigerated storage will not reduce bacterial contamination of product, will only slow growth of bacteria present

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

CRITICAL LIMITS

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

Is this step a CCP?

YES Or NO

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Responsibility

Records

Krystian Kobus / Craig Parker

FM03 TEMPERATU RE CHECK

Visual check of fridge temperature. Check meat temp with calibrated thermometer (sanitised)

Twice daily start & end of work period

Check stock rotation, all meats labelled and within date Check use of designated workwear and hand washing procedures. Visual checks

Daily at start and end of work period

FM05C/a CLEANING CHECK

Check cleaning schedule for kitchen followed correctly. Visual check

Daily

FM02 - Batch number info Stock take Excel sheet.

Procedure Destroy suspect meats. Adjust/repair fridges. Destroy suspect meats. Retrain staff, review rotation policy. Reclean, retrain staff, review procedures

Responsibility Butchery mngr

Records Butchery diary notes Training matrix

PROCESS STEP: Step 9 FOOD SAFETY HAZARD AND CAUSE Growth of food-poisoning & spoilage in meats prior to delivery due to falling outside the safe temperature ranges. Cross contamination by bacterial/ physical/chemical processing equipment and food contact surfaces

CCP DETERMINATION

Delivery to wholesale customers

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE Delivery within clean vehicles, refrigerated. Delivery vehicles maintained regularly for refrigerator function by approved dealer + also manually monitored regularly by cross-checking with manual temperature check.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Deliveries to be below <2 degrees for mincemeat

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Minimise transfer time from delivery vehicle to customer chills <10 mins Ensure regular maintenance checks for vans to take place daily and are recorded.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Q1: JUSTIFICATION

YES Or NO

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

no

Q2: JUSTIFICATION

Bacterial numbers are unlikely to increase during transportation due to short distances & refrigerated conditions. Bacterial transfer can occur however, from the delivery vehicle and numbers may increase if transfer times from vehicle to customer’s chills are extended.

yes

Correct cleaning and maintenance of equipment as mentioned in company policy.

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP? Yes

CRITICAL LIMITS Delivery below <2 degrees All meats delivered with packaging in sound condition, correctly labelled with our EC ID mark and dated.

Q3: JUSTIFICATION

There is no further process under our control that will reduce contamination to an acceptable level.

no

This step IS a CCP

MONITORING Procedure Delivery vehicle automatic temperature onitoring. Temps recorded at start and end of delivery. Meats signed for by customer upon delivery. Laser gun taken in van as a precaution.

Frequency Every delivery

Responsibility Individual driver answering to Nick Iles

CORRECTIVE ACTIONS Records

Procedure

VM03

Abort delivery and return to WS unit

KOOLTECH maintenance records.

Inform FSA of issue.

Responsibility Nick Iles

Records Delivery diary notes VM03

HACCP VERIFICATION RECORD DATE

TYPE OF DOCUMENTATION OR WORKING PROCEDURE CHECKED

CORRECTIVE ACTION REQUIRED

CORRECTIVE ACTION CARRIED OUT BY

SIGNED

SHEET NO:

zx

HACCP REVIEW YES Does the scope accurately describe the process?

If No – amend Plan.

Does the process stage correspond to the flow diagram?

If No – amend Plan.

Are controls valid for each hazard – Microbiological, Chemical and Physical?

If No – amend Plan.

Do the CCPs remain the same?

If No – amend Plan.

Are critical limits adequate?

If No – amend Plan.

Are monitoring procedures still effective for each CCP?

If No – amend Plan.

Are appropriate corrective actions identified?

If No – amend Plan.

REVIEW RECORD

NO

Review Carried Out By:

Position:

Signed:

Date Of Review:

AMENDMENT REQUIRED: Yes or No (If Yes, amend Plan then carry out validation)

Date Of Next Review:

Ruby & White HACCP Plan HACCP people

Business Name: Ruby & White Business Address: Unit 5B, Kingsland Trading Estate, St Phillips, Bristol, BS2 0JZ HACCP Study For (Process or Procedure): Raw sausage meat/sausages prep Date of Preparation: 19 / 07 / 2014 (D/M/Y) Revised & Updated : 11/ 12 / 2014 (D/M/Y)

Team Leader:

Dave Kelly

Role in company

Butchery Manager

Team Member 1: Role in company

Team Member 2:

Craig Parker Wholesale butcher manager

Krystian Kobus Wholesale Production Manager

Role in company

Team Member 3:

Nick Iles

Role in company

Transport team leader

PROCESS STEPS HACCP PLAN FOR: Sausage meat & sausages

Step 1: Purchase, delivery & receipt of fresh meat

This HACCP plan was prepared by: Dave Kelly Date of preparation 19/07/2014 (D/M/Y/) / Revised & Updated : 11/ 12 / 2014 (D/M/Y) 1)

Scope of Study: Biological Safety: The main aim of this HACCP study is to prevent, eliminate or reduce the microbiological contamination of food and to reduce the potential for growth.

2) Physical and Chemical Safety: To avoid the introduction of physical and chemical contaminants onto any food. Details of Process: Display and serve from fresh meat counter This HACCP plan covers the manufacture and production of sausages, from meat sourced and delivered by reputable supplier in the form of carcasses, quarters, primals or cuts. The storage of raw meats under appropriate refrigeration conditions & preparation for sale within the Butchery Room at controlled temperatures. The prepared raw meat is then available for direct sale to wholesale customers.

Step 2 Storage in fresh meat chiller

Step 3 Debone & Prepare for retail sale or further processing

Step 4 Meat cut into 5� Cubes

Step 5 meat pushed through mincer for 1st cycle, then 2nd

Step 6 – 3rd cycle, minced with sausage mix

Step 7 4th cycle, minced into clean tray then into sausage filler

Step 8 Sausage meat is then pumped into natural cases & set

Step 9 Storage of prepared meat in chiller Details of storage: Raw meat is stored in the raw meat chiller prior to inspection. Vacuum packed / Prepared trim, created from diced and sliced raw meats are held at chilled temperatures prior to sale & delivery. Details of use and customer: Raw meat cuts are preparations are sold directly to retail customers or delivered to wholesale customers, including local restaurants and hotels, ensuring the cold chain is adhered to AT ALL TIMES.

Step 10 Delivery to wholesale customers

PROCESS STEP: Step 1 Purchase, delivery & receipt of fresh

CCP DETERMINATION

meat

FOOD SAFETY HAZARD AND CAUSE Break in the Cold Chain causing meat products to fall outside of safe temperature ranges Growth of food poisoning bacteria (eg E Coli 57) and spoilage within meats prior to delivery. Cross contamination by physical/ chemical contaminants prior to delivery. Physical/chemical/bacterial contamination of dry goods and sausage casings from damaged packaging, product being of poor quality and any exposure to elements.

Is this step a CCP? YES

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE All meats and dr goods purchased from selected and approved EC licenced suppliers. Delivered by clean, refrigerated vehicles. Delivery temp at or below <4 degrees

YES Or NO

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Staff training. Staff hygiene rules including handwashing and company hygiene policy. Dry Goods delivery checks : visual check of all packaging / BB dates and overall appearance/quality of product. Recorded on FM02 records.

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly.

Does this process step prevent, No eliminate or reduce contamination to an acceptable level? QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Minimise transfer time from delivery vehicle to raw meats chill storage. Less than 10 minutes.

Q1: JUSTIFICATION

Q2: JUSTIFICATION

YES

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

MONITORING

Bacterial contamination could occur prior to delivery. The delivery process itself occurs at ambient temperature, but the time taken is short and there is very low risk of bacterial growth. Bacterial transfer can occur however, from the delivery vehicle. Q3: JUSTIFICATION There is no further process under our control that will reduce bacterial contamination.

no

This step IS a CCP

CORRECTIVE ACTIONS

CRITICAL LIMITS Procedure Selection of EC approved meat suppliers

Supplier selection process.

No unpleasant, noxious odours indicating spoilage. Delivery at or lower than <4 degrees.

Assessment of incoming meat deliveries

.

Check internal meat temperature on delivery + prior to use with calibrated, disinfected thermometer probe.

Frequency

Each supplier Each delivery Two samples per delivery

Responsibility

GOODS IN : Dave Kelly

Records

Procedure

FM02

Reject delivery

PRODUCT INTAKE FORM

Review supplier approval INFORM FSA & LOCAL AUTHORITY

Responsibility

Butchery mngr

Records FM02 PRODUCT INTAKE FORM

PROCESS STEP: Step 2 Storage in Fresh meat chiller

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

FOOD SAFETY HAZARD AND CAUSE

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Chill storage <3c in designated chiller.

Contamination by bacteria from poor staff hygiene Cross contamination by bacteria/physical/chemical contaminants from within butchery chill

Is this step a CCP? Yes

Correct rotation (FIFO)

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

Product storage at <3c in designated chiller Used within date as indicated by supplier packaging Strict first in, first out stock control system Staff hygiene rules& cleaning schedule followed

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

MONITORING

Refrigerated storage will not reduce bacterial contamination of product, will only slow growth of bacteria present

yes

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Frequency

Responsibility

Visual check of fridge temperature. Check meat temp with calibrated thermometer (sanitised)

Twice daily start & end of work period

Krystian Kobus / Craig Parker

Check stock rotation, all meats labelled and within date Check use of designated workwear and hand washing procedures. Visual checks

Daily at start and end of work period

TEMPERATU RE CHECK

Daily

CLEANING CHECK

Check cleaning schedule for kitchen followed correctly. Visual check

Q1: JUSTIFICATION

Q2: JUSTIFICATION

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Staff training Staff hygiene rules and company hygiene policy must be followed

CRITICAL LIMITS

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

Records FM02 GOODS IN

FT03 -

FM05C

Procedure Destroy suspect meats. Adjust/ repair fridges. Destroy suspect meats. Retrain staff, review rotation policy. Reclean, retrain staff, review procedures

Responsibility Dave kelly

Records Butchery diary notes

Training matrix

PROCESS STEP: Step 3 Debone & Prepare for retail sale or further

CCP DETERMINATION

processing

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Small batches made to reduce amount of stock exposed to spoilage bacteria. (Progressive workflow adopted) Minimise time held at controlled temperature - Required meat cuts prepared in <60 mins

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Yes

CRITICAL LIMITS

MONITORING Procedure

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed Check cleaning schedule for butchery followed correctly. Visual check

Frequency Movement of each batch recorded Daily

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

YES Or NO

Responsibility Krystian Kobus / Craig Parker

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records

Procedure

FM02 GOODS IN

Destroy suspect meats. Review processes

FT03 TEMPERAT URE CHECK

Destroy suspect meats. Retrain staff,

FM05C CLEANING CHECK

Reclean, retrain staff, review procedures

Responsibility Dave kelly

Records Butchery diary notes Training matrix

PROCESS STEP: Step 4 Meat cut into 5� Cubes, ready for mincing

CCP DETERMINATION

machine

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Meat is prepared in the cutting room, under a controlled ambient temperature of <8-10 degrees.

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Small batches made to reduce amount of stock exposed to spoilage bacteria. Progressive workflow adopted. Minimise time held at controlled room temperature. Required meat cuts prepared in <60 mins Strict good hygiene butchery practices maintained at all times including hand-wash procedures. Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Yes

CRITICAL LIMITS

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed Check cleaning schedule for butchery followed correctly. Visual check

Frequency Movement of each batch recorded Daily

Responsibility Krystian Kobus / Craig Parker

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records FM02 goods in FT03 TEMPERATU RE CHECK

FM05C CLEANING CHECK

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff, Reclean, retrain staff, review procedures

Responsibility

Records

Butchery mngr

Butchery diary notes Training matrix

PROCESS STEP: Step 5 meat pushed through mincer for 1st cycle, then

CCP DETERMINATION

2nd cycle

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Minimise time held at controlled room temperature <8-10 degrees. Required meat cuts prepared in <60 mins

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Physical contaminants entering the mix through the mincer.

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules Ensure regular maintenance checks take place & parts are functioning correctly. Small batches made to reduce amount of stock exposed to spoilage bacteria

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Yes

CRITICAL LIMITS

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Frequency Movement of each batch recorded Daily

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level? Is this step a CCP?

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Responsibility Krystian Kobus / Craig Parker

Records FM02 goods in

FT03 TEMPERATU RE CHECK RE CHECK

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff,

FM05C

Check cleaning schedule for butchery followed correctly. Visual check

CLEANING CHECK

Reclean, retrain staff, review procedures

Responsibility Dave Kelly

Records Butchery diary notes Training matrix

PROCESS STEP: Step 6 – 3rd cycle, minced with sausage mix

FOOD SAFETY HAZARD AND CAUSE Growth of food-poisoning & spoilage bacteria due to too long at room temperature. Contamination by bacteria from poor staff hygiene & unclean contact surfaces/ equipment Physical contaminants entering the mix through the mincer. Sausage mix is out of date and/or of poor quality

Is this step a CCP? Yes

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE Minimise time held at controlled room temperature. Required meat cuts prepared in <60 mins Strict good hygiene butchery practices maintained at all times including hand-wash procedures. Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules Ensure regular maintenance checks take place & parts are functioning correctly. Mix sourced from reputable supplier, checked on delivery for packaging damage. Recorded on delivery records inc BB date.

Small batches made to reduce amount of stock exposed to spoilage bacteria

CRITICAL LIMITS

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Daily

Responsibility Krystian Kobus/ Craig Parker

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Frequency Movement of each batch recorded

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

MONITORING Procedure

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records VM03

Fm02

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff,

Cleaning schedule followed Dry Goods deliveries recorded on Product Intake records

Check cleaning schedule for butchery followed correctly. Visual check

Reclean, retrain staff, review procedures

Responsibility Dave kelly

Records Butchery diary notes Training matrix

PROCESS STEP: Step 7: 4th cycle minced into clean tray then into sausage

CCP DETERMINATION

filler

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Minimise time held at controlled room temperature. Required meat cuts prepared in <60 mins

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Physical contaminants entering the mix through the mincer. Tray is not clean and/or damaged

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules Ensure regular maintenance checks take place & parts are functioning correctly. Small batches made to reduce amount of stock exposed to spoilage bacteria Always use clean utensils/trays

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Yes

CRITICAL LIMITS

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Frequency Movement of each batch recorded

Responsibility Krystian Kobus / Craig Parker

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP?

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records FM02

FT03

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff,

Daily Reclean, retrain staff, review procedures

Check cleaning schedule for butchery followed correctly. Visual check

Responsibility DAVE KELLY

Records Butchery diary notes

PROCESS STEP: Step 8: Sausage meat is then pumped into natural cases

CCP DETERMINATION

& set

FOOD SAFETY HAZARD AND CAUSE

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to too long at room temperature.

Minimise time held at controlled room temperature. Required meat cuts prepared in <60 mins

Contamination by bacteria from poor staff hygiene & unclean contact surfaces/equipment

Strict good hygiene butchery practices maintained at all times including hand-wash procedures.

Natural cases are out of date and/or poor quality Physical contamination from sausage filler machine

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules Ensure regular maintenance checks take place & parts are functioning correctly. Small batches made to reduce amount of stock exposed to spoilage bacteria Source casings from reputable supplier & check date/condition prior to use

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Yes

CRITICAL LIMITS

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Swift movement of meats through processing.

Continual monitoring as meat moves through butchery.

Staff hygiene rules followed

Check use of designated work wear & hand washing procedures. Visual check

Cleaning schedule followed

Frequency Movement of each batch recorded

Responsibility Krystian Kobus / Craig Parker

Q1: JUSTIFICATION This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

MONITORING Procedure

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Is this step a CCP?

YES Or NO

There is significant risk that the product could become contaminated at this stage. Extra vigilance is needed regarding good hygiene practices. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records FM02

Procedure Destroy suspect meats. Review processes Destroy suspect meats. Retrain staff,

Daily Reclean, retrain staff, review procedures

Check cleaning schedule for butchery followed correctly. Visual check

Responsibility DAVE KELLY

Records Butchery diary notes Training matrix

PROCESS STEP: Step 9:Storage of prepared meat in chiller

FOOD SAFETY HAZARD AND CAUSE

CCP DETERMINATION QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE

Growth of food-poisoning & spoilage bacteria due to inadequate temperature control or too long in butchery chill.

Chill storage <3c

Contamination by bacteria from poor staff hygiene

Staff training Staff hygiene rules and company hygiene policy must be followed

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3

Correct cleaning and maintenance of chill as stated in company cleaning & maintenance schedules

Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

Cross contamination by bacteria/ physical/chemical contaminants from within butchery chill

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

Correct rotation (FIFO)

YES Or NO

no

Is this step a CCP? Yes

CRITICAL LIMITS Product storage at <3cin designated chiller Strict first in, first out stock control system Staff hygiene rules& cleaning schedule followed

MONITORING Procedure

Frequency

Responsibility

Visual check of fridge temperature. Check meat temp with calibrated thermometer (sanitised)

Twice daily start & end of work period

dave kelly

Check stock rotation, all meats labelled and within date Check use of designated workwear and hand washing procedures. Visual checks

Daily at start and end of work period

craig parker

Check cleaning schedule for kitchen followed correctly. Visual check

Daily

krystian kobus

Refrigerated storage will not reduce bacterial contamination of product, will only slow growth of bacteria present

Q2: JUSTIFICATION

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Q1: JUSTIFICATION

Inadequate temperature controls, poor stock rotation and cross-contamination can all increase levels of bacterial contamination Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records FM02 Goods In used to track throughout

Procedure Destroy suspect meats. Adjust/repair fridges. Destroy suspect meats. Retrain staff, review rotation policy. Reclean, retrain staff, review procedures

Responsibility dave kelly

Records Butchery diary notes

PROCESS STEP: Step 10 FOOD SAFETY HAZARD AND CAUSE Growth of food-poisoning & spoilage in meats prior/during to delivery due to produce falling outside the safe temperature range. Cross contamination by bacterial/ physical/chemical processing equipment and food contact surfaces

CCP DETERMINATION

Delivery to wholesale customers

QUESTION 1 If YES This step is a CCP If NO Move on to next question

CONTROL MEASURE Delivery within clean vehicles, refrigerated. Delivery vehicles maintained regularly for refrigerator function by approved dealer + also manually monitored regularly by cross-checking with manual temperature check. Deliveries to be below <4 Minimise transfer time from delivery vehicle to customer chills <10 mins Ensure regular maintenance checks for vans to take place daily and are recorded.

Does this process step prevent, eliminate or reduce contamination to an acceptable level?

YES Or NO

no

QUESTION 2 If NO this step is not a CCP If YES Move on to Q3 Could the product become contaminated in excess of acceptable levels or increase to unacceptable levels?

yes

QUESTION 3 If YES This step is NOT a CCP If NO This step is a CCP

Is this step a CCP? Yes

CRITICAL LIMITS Delivery below < 4 All meats delivered with packaging in sound condition, correctly labelled with our EC ID mark and dated.

MONITORING Procedure Delivery vehicle automatic temperature monitoring. Temps recorded at start and end of delivery. Meats signed for by customer upon delivery

Frequency

Responsibility

Every delivery individual driver

This step will not reduce bacterial contamination. Physical contamination will be identified and dealt with accordingly

Q2: JUSTIFICATION

Correct cleaning and maintenance of equipment as mentioned in company policy.

Will a subsequent process step prevent, reduce or eliminate contamination to an acceptable level?

Q1: JUSTIFICATION

Bacterial numbers are unlikely to increase during transportation due to short distances & refrigerated conditions. Bacterial transfer can occur however, from the delivery vehicle and numbers may increase if transfer times from vehicle to customer’s chills are extended. Q3: JUSTIFICATION

no

There is no further process under our control that will reduce contamination to an acceptable level. This step IS a CCP CORRECTIVE ACTIONS

Records VM03 KOOLTECH maintenance records

Procedure Abort delivery and return to WS unit Inform FSA of issue.

Responsibility Nick Iles temperature checks + recording Issues - mngr

Records Delivery diary notes VM03

HACCP VERIFICATION RECORD DATE

TYPE OF DOCUMENTATION OR WORKING PROCEDURE CHECKED

CORRECTIVE ACTION REQUIRED

CORRECTIVE ACTION CARRIED OUT BY

SIGNED

SHEET NO:

HACCP REVIEW YES Does the scope accurately describe the process?

If No – amend Plan.

Does the process stage correspond to the flow diagram?

If No – amend Plan.

Are controls valid for each hazard – Microbiological, Chemical and Physical?

If No – amend Plan.

Do the CCPs remain the same?

If No – amend Plan.

Are critical limits adequate?

If No – amend Plan.

Are monitoring procedures still effective for each CCP?

If No – amend Plan.

Are appropriate corrective actions identified?

If No – amend Plan.

REVIEW RECORD Review Carried Out By:

Position:

Signed:

Date Of Review:

Date Of Next Review:

NO

AMENDMENT REQUIRED: Yes or No (If Yes, amend Plan then carry out validation)

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