critical control points & recall plan

NO.
Critical limit
Monitoring procedures
Corrective actions
CCP1


Metal detection

(solid filling)
1.No ferrous metal³1.2mmǿ
2.No non-ferrous metal³2.0mmǿ
What
Detect metal in plastic cups filled with solid items.
--When metal objects are detected, the “channeliser” will segregate the affected cup
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.


How
Metal detector
When
At the end of manual filling process.
Where
On the conveyer belt leading to filling machine.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
((Liquid filling)
What
Detect metal in gravies passing through piping to filling machines.
--This will activate the alarm and the executive will be notified.
--The foreign matter will be removed and an investigation has been conducted by the team to identify the source of contamination.
--Production will only be resumed after approval of executive or manager in charge.


How
Metal detector
When
During the pumping of the gravies to the filling machines.
Where
At the start of the pipes leading from kettle to the filling machines’ hopper.
Who
1.Operator to take note of any alarm from detector.
2.Executive or supervisor to record any detected metal pieces.
CCP2
Sealing
Of pouches
175-180˚C
Specific control measure: no commence of sealing process is allowed when the required temperature is not reached.
What
Check the temperature settings are correct
--If any required temperature cannot be achieved/maintained during equipment malfunction.
1.Do not start the process.
2.Inform Maintenance Team immediately to rectify and service the equipment.
If the fault cannot be remedied due to major breakdown and ect:
1.Maitenance will arrange for external professional engineer to repair.
2.The machine will be stopped until further instruction from manager.
3.The activity at this machine will be transferred to another line.

How
Check the digital reading of the thermometer.

When
Before the start of production and every 2hours during production.
Who
Supervisor



CCP3
Sterilization/
Retorting
121˚C for 45 minutes
at 0.188-0.212mPa
What
Check the correct sterilization parameter.
--If the sterilization setting incorrect due to wrong pattern card being used:
1.Before start of sterilization, change to correct card immediately.
2.After start of/during process: report to Production Executive immediately.
-Production executive will use the engineering card to overwrite and correct the setting to the required parameters.
3.If sterilization process already completed and the parameters used is higher than the required specification,
-Quarantined the product for sensory evaluation and decision by manager.
4.If the sterilization process already completed and the parameter used is lower than the required specification,
-Quarantined the product for microbiological testing and decision by manager.
How
Check the parameter shown on the control panel screen.
When
Before the start of each sterilization cycle
Where
At the control panel of the retort sterilizer.
Who
Retort operator or Production executive.


Recall procedures:

A product recall can be voluntary in the event that company detects the defect through its QA and HACCP Plan or involuntary if the Authority (NEA or AVA) or the customers detect the problem.
A recall can be categorized into the following 3 categories:
Class І: The product will be probably cause serious public health hazards, perhaps even death e.g. Contamination with pathogenic bacteria or toxic materials.
Class П: The product may cause health hazards, but is unlikely to lead to serious injuries or illnesses, e.g. Contamination with microorganism and product spoilage.
Class Ш: The product will not cause a public health hazards, e.g. Non-critical labeling errors.
In a event of a Class І product recall, the senior management will activate the necessary arrangement to recall the product immediately.
In the event of a Class П product recall, the senior management will be informed and the business director or the Food preparation manager will initiate the product recall.
In the event of Class Ш product recall, the business director or the Food preparation manager will be informed and the QA manager will initiate the product recall.
If the in-house monitoring program detects unsafe product from the plant, the QA manager will activate key members of Quality Planning Team to collect, analyze and evaluate all information related to the product.
Upon confirmation that the particular production lot falls into Class І or Class П, the QA Manager will report to the senior management and obtain approval to recall the affected products.
The QA manager will then call for a meeting, chaired by Food preparation manager to activate the recall program. The Operation manager, Warehouse manager, Export manager, catering manager and the Corporate Communication Manager will be provided with details of the affected production lot.
The warehouse manager will be responsible for quarantining all existing stock of the affected products in the warehouse while the Sales manager will coordinate with the customers to recall the affected products from the customers. Warehouse manager will also be responsible for the retrieval of affected products from customers.
If the products involves overseas sale, the Export manager will liaise with the oversea distributor/agents and advise them to arrange for a product recall. Once the products have been recalled to the distribution center, the overseas distributor may then inform the company and the Export manager will lead a QA team to conduct a thorough investigation on the recalled product.

Packaging condition: thick army green pouches 200g—300g
Product shelf life: 1—2years
Microbial specifications:
Sterilized product: --No brown pouches for commercial sterility test
--“Negative” results for TPC tests

Pasteurized product: --<10ˆ5 cfu/g TPC
--<10ˆ2 cfu/g Yeast Plate Count test
--<10ˆ2 cfu/g Mould Plate Count
Chiller: 4.0—4.5˚C

Freezer:-15.0-- -18.0 ˚C

Retort: 121˚C--125˚C for 45 minutes
Pressure:0.188mPa—0.212mPa