Rajkumar Honey HACCP Plan

1 Company Form # PD-1 Location : Rajkumar Apiaries and Honey Works Product(s): Honey Product Description Product: Honey Code: Packaging: 250 ml plastic bottles and 5 gallon plastic pails (container) Preservation Method: Product kept in air tight containers Storage Requirements: To be kept in a cool dry place between 20 0 c - 25 0 c Distribution System: Honey is bottled, placed in cardboard boxes and is delivered to wholesale entities Honey is also placed into five gallon pails (containers) and is exported to overseas for further processing Intended Use: Direct consumption by consumers Exported for further processing Consumers: Adults and Children over 1 year of age can use the honey. Additional Information: Product Characteristics: Moisture Content (Max 18.5%) PH (3.9) Water Activity aw (0.58) and Hydrogen Peroxide (7-31 PPM) Reviewed By: ………………………………………………………………… Date: ………………………………………………………………. 2 Company Form # PD-2 Location : Rajkumar Apiaries and Honey Works Product(s): Honey Ingredient List Product: Honey Code: Ingredients (descending order of predominance by weight): Pure Honey Reviewed By: ………………………………………………………………… Date: ………………………………………………………………. 3 4 Company Form # HA-1IN Location : Rajkumar Apiaries and Honey Works Product(s): Honey Hazard Analysis Worksheet – Ingredients and Materials (1) Ingredient / Material (2) Identify potential hazards Introduced, controlled, or enhanced by this ingredient /material (3) Are any potential food-safety hazards significant? (Yes/No) (4) Justify your decision for column 3 (5) What measure(s) can be applied to prevent, control, or reduce to acceptable levels the significant hazards in the finished product? (6) Is this a critical ingredient or material? (Yes/No) Raw (Pure) Honey Biological- Pathogens ( E. coli 0157:H7, Listria, Salmonella) Clostridium Botulinum Yes Pathogens may be present on harvested Honey. Honey has anti-microbial properties that inhibit the growth of microorganisms. Honey is expected to have low numbers of pathogens. Clostridium Botulinum toxin may result in illness / death in children under 1 yr of age. A Labels used must have the disclaimers stating not to feed children less than 1 yrs of age with honey. This must be on every label and be documented and verified. All labels used must have. Products with labels without disclaimer cannot leave the MFG premises. . Yes Chemical – Pesticides Residue use in No Bee keeping chemicals- formic acid, lactic acid, thymol and No 5 Bee keeping menthol are generally considered food safe Very limited number of (MRL) Standards for residue in honey - Raw Honey Physical- Wood, Sand, Dust, Nails from frames, wire and plastic from combs Yes Foreign matter was seen in extracted honey before. A clean white cloth is used to strain honey just after extraction (centrifuge) after which it is left to stand in storage containers. No Plastic Bottles Packages Biological- Contamination with Human Pathogen Yes Pails and plastic bottles are protected from contamination by micro-organisms. Handlers are trained to handle packages hygienically. Packaging materials received are properly examined. Chemical- Leaching of chemical from (Pet) bottles. No In the past leaching from plastic was observed Purchase of new bottles from recognized supplier. No Physical- Plastic fragments, dust and foreign matter. Yes No major issue with plastic fragments, dust and or foreign matter on new bottles were experienced in the past Purchase of new food grade plastic bottles. No 6 Company Form # HA-1P Location : Rajkumar Apiaries and Honey Works Product(s): Honey Hazard Analysis Worksheet – Process Steps (1) Processing Step (2) Identify potential hazards Introduced, controlled, or enhanced at this step (3) Are any potential food-safety hazards significant? (Yes/No) (4) Justify your decision for column 3 (5) What measure(s) can be applied to prevent, control, or reduce to acceptable levels the significant hazards in the finished product? (6) Is this step a critical control point (Yes/No) Harvesting / Collecting Biological- Human Pathogen No Honey has anti-microbial properties that discourage the growth and persistence of any microorganism. No Chemical- Smoke Soot, Pesticide Residue Yes In the past chemical and process use to handle bees and harvest honey, have contaminated the product. Only recommended substances will be used to treat bees that are used for harvesting honey. No Physical- Soil, Insect , Animal In the past and based on Honey is strained to remove 7 Parts, wood, wire, Parts of comb. Yes experience such items /particles were found in harvested honey. physical hazards after extraction. No Receiving Biological- Human Pathogen No Honey anti-microbial properties, inhibits the growth of microorganisms. - No Chemical- Detergent and sanitizing chemical in transporting containers Yes No major issue with contaminated containers in the past. GMP Pre-requisite program to ensure all transporting containers are washed and rinsed properly. No Physical- Soil, Insect, Animal Parts, Wood, Wire, Parts of Combs Yes These hazards have been associated with honey in the past. Settling and Straining in subsequent step removes the identified hazards No Centrifugal Extraction from Combs Biological- Human Pathogen No Honey properties prevent the growth of micro-organisms. - No Chemical- Dissolve metal, reaction with honey from extractor. Yes Extractor used is made of galvanized steel (zinc) and is painted; flaked paint area can allow honey to react with extractor material. Changing the extractor / centrifuge to stainless steel material or PVC (Plastic). No 8 Physical- Insect pieces, soil, wire, Plastic and metal. Yes It has been observed over time that the listed impurities are present in honey after extraction Honey is left to be processed (settling) for 3-5 days to remove impurities No Straining Biological- None No Chemical-None No Physical- Debris, Insect pieces and other organic debris Yes After extraction, honey has been associated with the listed physical hazards at this facility. Straining cloth is well protected when not in use and comes from a reputable source. Changes are made to the cloth used monthly. A clean white cloth is used to strain honey just after extraction (centrifuge) then left to stand in storage container. No Biological- None Chemical- Detergent Residue from previously Yes Storage containers were improperly cleaned in the past All previously used containers will be properly No 9 Processing (Settling) used storage container Resulting in contamination / discoloration of honey. cleaned at all times and inspected. Physical-Metal, and Debris in Re-used tanks. Yes Settling container have been, improperly coated or cleaned in the past. Containers will be properly coated and kept cleaned at all times. How, when and with what chemical containers are cleaned would be documented. No Re-Straining Biological- None Chemical- None Physical- Foreign matter, insect parts or debris Yes Foreign objects can enter product from processing container or because the strainer used before was damaged Product will be monitored after placing into retail packages and processing tanks will be monitored. Yes Bottling / Capping Biological – Human Pathogen From handling / Manual filling. Yes Honey does not allow micro- organism to grow and multiply. All workers will undergo Food Handler’s hygiene training before working at filling stations. Workers at filling stations will observe strict personal hygiene practices and hand washing practices No 10 Chemical-None Physical- Human Hair in product In the past human hair was found in the product. All workers will undergo food handler’s hygiene training before working at filling stations. Workers will be responsible for using protective clothing at all time and use hair nets at filling stations. No Labeling Biological- Clostridium Botulinum Spores Yes Clostridium Botulinum Spores present in Honey has been associated with the deaths of children under 2 years of age in the past. All label, will contain a Disclaimer, stating “Not to be given to Children Under 2yrsof Age” All labels coming into premises and used by worker must include such disclaimer. Yes Chemical –None Physical-None Storage Biological- None No Honey has a natural inhibitor that prevents bacteria growth on standing. No Chemical- None No Physical-None No Pre-requisite No 11 Company Form # HA3 Location : Rajkumar Apiaries and Honey Works Product(s): Honey Hazard Analysis Worksheet Ingredients Ingredient (By)order of predominance Potential hazards Risk (H=High, M= Moderate, L=Low) Significant Hazard? (Yes/No) Preventive programs or control measures that can be applied Sensitive ingredient? (Yes/No) Probability Severity Honey Biological-Pathogen Chemical- Pesticide Chemical Physical- Debris and Foreign matter High High High High Low Moderate Yes No Yes Label Disclaimer Use of a Strainer Yes Packaging Material Biological-None Chemical- Leaching Physical- Debris Low Low Low Low Use of new bottles Use of clean bottles No No 12 Company Form # HA4 Location : Rajkumar Apiaries and Honey Works Product(s): Honey Hazard Analysis Worksheet Processes Processing Step Potential hazards at this step Risk (H=High, M= Moderate, L=Low) Significant Hazard? (Yes/No) What measures(s) can be applied to prevent, control or reduce to acceptable level the significant hazards? CCP? (Yes/No) Probability Severity Harvesting Biological-Pathogens Chemical-Pesticide Residue Physical-Debris and foreign matter High Moderate High High Low Moderate Yes No Yes Use of a Label disclaimer Very little information on the hazard exists Use of a strainer Yes No No Receiving Biological-Pathogen Chemical- Detergent and Sanitizing Chemicals Physical- Debris and foreign matter Moderate Moderate Moderate Low Low Moderate No No Yes Natural Composition of honey inhibits pathogen growth. GMPs and training for workers Use of a strainer to removed debris and foreign matter 13 Extraction from Combs Biological-Pathogen Chemical- Dissolved metal Physical- Debris and foreign matter Moderate Moderate Moderate Low Low Moderate No No Yes Natural Composition of honey inhibits pathogen growth. No data to support action Use of a strainer to removed debris and foreign matter No No No Straining Biological- None Chemical-None Physical- Debris and foreign matter Moderate Low No Clean white cloth is used for straining No Processing Biological- None Chemical- Detergent residue Physical-Debris from previously used containers Low Moderate Low Low No N0 Properly cleaned storage containers Properly Cleaned Storage containers No No Re-straining Biological- None Chemical-None Physical- Debris and foreign Matter accumulated during processing, insect parts Low Low No A clean white cloth used to strain Honey before bottling. No 14 Bottling / capping Biological- Human Pathogen Chemical-None Physical- Human Hair in Product Moderate Moderate Low Low No No The natural characteristics of honey prevent the growth of pathogen. Working training and use of protective clothing. No Labeling Biological- Clostridium Butulinum Spores Chemical-None Physical- None Moderate High Yes Use of a disclaimer on the Label Yes Storage Biological- Pathogen Growth Chemical-None Physical- None Low Low No Pathogen growth are inhibited naturally in honey No 15 IMGREDIENT HAZARD ANALYSIS Product or Process Name: List all Ingredients used in the product, process or plant Identify Known hazards Likely Risk (likelihood & Severity) H=High, M=Medium, L=Low Likelihood Severity Is this a Critical Ingredient (1) (Yes/No) Identify Prerequisite Programs or process steps to reduce or eliminate known hazards B C P B C P B C P B= Biological, C=Chemical, P=Physical Instructions: Identify any likely potential hazards associated with incoming material (ingredients or packaging material), rework, and preservatives, then assess to the best of your knowledge the likely risk associated with these materials and identify any specific preventive programs or corrective steps that eliminate or reduce to an acceptable level those risks in the finished product. (1) Critical Ingredient: Any ingredient, packaging material, rework, or preservative that has a High (H) and /or Medium (M) likelihood or severity risk factor. Any item identified as”Critical” must be brought forward to Receiving on the Process Hazard Analysis Form. 16 PROCESSED HAZARD ANALYSIS (1) (2) (3) (4) (5) (6) List each process step from the Process Flow Diagram. (For Receiving only, bring forward each ingredient from the Ingredient Hazard Analysis that was determined to be a Critical Ingredient.) Does this ingredient or process step INTRODUCE a potential food safety hazard? Identify here. (be as specific as possible when listing the hazard) Is this hazard CONTROLLED by a Prerequisite Program or process step? If YES, identify the Program or process. If a prerequisite Program or process is identified, do not complete Columns 4-6 and go to the next process step. If NO, go to Column 4. Is this hazard ELIMINATED by a subsequent (later) process step? If YES, this step is NOT a CCP. Identify the subsequent process step in Column 5 and proceed to the next process step. If the hazard is eliminated at this step (no subsequent elimination step) enter NO and go to Column 6 and assign a CCP number. Identify the last process step that will eliminate the potential hazard. (Example: metal detector, filter, cooking, pasteurization Assign a CCP number when the answer in Column 4 is NO. Otherwise leave blank Honey Biological - Clostridium Botulinum Spores are associated with raw honey. No No CCP – 2 Harvesting Biological- Human Pathogens Chemical- Smoke Soot, Pesticide Physical- Soil, Insect , Animal Parts, wood, wire, Parts of comb. No Yes Only approved technique used to remove bee from hives No Yes Yes Honey naturally inhibits the growth of micro organisms. The straining of honey 17 Receiving Biological-Human Pathogens Chemical- Detergent and Sanitizing residue. Physical -Particles, insect pieces, soil, wire, Plastic and metal. No Yes No Yes Yes Honey naturally inhibits the growth of micro organisms The straining of the honey before processing. Centrifugal Extraction Biological-Human Pathogens Chemical- Dissolve metal, reaction with honey from extractor. Physical- Insect pieces, soil, wire, Plastic and metal. No Yes Change the type of extractor used to Stainless steel or PVC (Plastic) No Yes Yes Honey naturally inhibits the growth of micro organisms The straining of the honey before processing. Straining Biological- None Chemical- None Physical- Pieces of comb, wax particles, debris, insect pieces and other organic debris No Yes Using a clean white cloth for straining honey. 18 Processing Biological-None Chemical -Detergent Residue from re-used containers Physical- Debris from re-used tanks. Yes Effective cleaning, sanitation and inspection of storage containers before use. Yes Effective cleaning, sanitation and inspection of storage containers before use Re-straining Biological-None Chemical- None Physical- Debris and foreign Matter accumulated during processing, insect parts No No CCP-1 Bottling / Capping Biological-Human Pathogen Chemical- None Physical- Human hair No No Yes Yes Honey is a natural inhibitor to pathogenic micro-organism growth. The use of protective clothing and staff Hygiene training. Labeling Biological-Clostridium Botulinum Spores Chemical- None Physical- None No No CCP-2 Biological-None 19 Storage Chemical- None Physical- None 20 Company Form # HP-1 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Plan Summary Critical Control Point (CCP) Significant Hazard(s) Critical Limits for each Control Measure Monitoring Corrective Action(s) Verification Records What How Frequency Who Labeling Clostridium Botulinum Spores Monitor label content for appropriate wording. All labels will include statement “ It is not recommended that children under 1 year to consume this product” Labeled packages Inspection for presence of a label with statement regarding consumption Every Batch of Packaged honey will be monitored for the statement of consumption By persons working at the labeling station Change Label used without disclaimer Check all label records Records of Label without disclaimers Used are recorded. Re-Straining Insect parts, foreign matter and debris Honey is to be free of foreign matter, insect parts or debris more than 5 um. (Micron meters) in size. Foreign Matter, Debris, Insect parts. Workers at packaging station will look for contaminant s. Every Batch Packages will be inspected for contaminants Persons working at the packaging station. -Restraining -Change of straining cloth if damaged Check all batches for insect parts, foreign matter or debris in sizes more than 5 uM. Make a record if restraining or rework was conducted or if the straining cloth was changed. 21 Company Form # HP-2 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Plan Summary Critical Control Point (CCP) Significant Hazards Critical Limits for each Control Measure Re-Straining Insect Parts, Foreign Matter and Debris No foreign matter more than five Micron meters shall be in the honey. Labeling Clostridium butulinum No label must be used without this disclaimer “ Not to be used by children under 1 years of age” 22 Company Form # HP-3 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Plan Summary Critical Control Point (CCP) Significant Hazards Monitoring What How Frequency Who Re- Straining Insects parts, foreign matter and debris Honey Visual Examination Every 60 minutes 25 bottles will be examined for contaminants. Staff at the bottling station, who will be responsible for recording any deviation from specification. Labeling Clostridium Botulinum Presence of a label with appropriate statement regarding consumption Inspection for disclaimer Every 30 minutes 15 bottles will be examined for the label disclaimer. Staff at the label station and record any deviation. 23 Company Form # HP-4 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Plan Summary Critical Control Point (CCP) Significant Hazards Corrective Action(s) Re-Straining Insect parts, foreign matter and debris Re-strain / rework honey that has contaminants (foreign matter, insects parts or debris) Check the condition of cloths used for straining and replace if necessary Revisit Re-straining method and procedure to ensure it is effectively conducted Labeling Clostridium Botulinum Removed all labels that do not have a written disclaimer Re-label products that were labeled with incorrect label Discard incorrect label Ensure all remaining labels are checked for the correct information 24 Company Form # HP-5 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Plan Summary Critical Control Point (CCP) Significant Hazards Verification Records Re-straining Insect parts, foreign matter and debris -Quarterly review of the HACCP Plan -Weekly inspection by the Quality Control officer to ensure Re-straining procedure is functioning properly -Confirmation by the Quality Control officer that CCP (re- straining) is kept under control. All monitoring activity on re-straining are to be recorded Corrective action(s) taken in relation to re-straining are to be recorded Verification exercise, date performed and finding relative to re- straining are to be recorded Any modification to the CCP ‘Re-straining” must be recorded. Labeling Clostridium Botulinum Quarterly review of the HACCP Plan -Weekly inspection by the Quality Control officer to ensure That labels carry the statement “not to be consumed by children under 1 year of age” -Confirmation by the Quality Control officer that CCP (labeling) is kept within specification. All monitoring activity on labels are to be recorded Corrective action(s) taken in relation to labels are to be recorded Verification exercise, date performed and finding relative to labels are to be recorded Any modification to the CCP ‘Labels’ must be recorded. 25 26 Company Form # HC-1 Location : Rajkumar Apiaries and Honey Works Product(s): Honey HACCP Corrective Action Sheet Location Product Date Packaging CCP Line Deviation: Cause of Deviation: Immediate Corrective Action Taken: Product Disposition: Additional Corrective Actions to be Taken: Operator: Supervisor: Reviewer: Date Reviewed: