Quality Manual - PG

7/28/2019 Quality Manual - PG

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Logo Food Safety ManualPage

1/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date

MR / /01Apr07 PS / /01Apr07 MD / /01Apr07

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Bhole Baba Dairy Industries Ltd.AddressAligarh

Amendment Status

Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.

Revision Description of Revision Prepared Reviewed Approved

Status Date By Date By Date By Date

00 01.04.07 First Issue MR 01.04.07 PS 01.04.07 MD 01.04.07


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0. Profile

Bhole Baba Dairy Industries Limited (BBDIL) situated at Aligarh (Dist - Aligarh of Uttar

Pradesh) is having a pollution free environment and is blessed with a rich source of MILK

with potential for multifold increase in milk production. The milk available is surplus for

converting into value added products.

The surplus milk available from the various Milk sources in the milk-shed area is about 0.4

million liters per day as of now and proposes to reach 1 million towards the end of the year

2007.

BBDIL plans to set up a wide network of Bulk Coolers to gradually encompass its

area of procurement as one of the perspectives towards continual improvement in the

quality of incoming milk. This is to ensure procurement of best quality milk by

providing immediate chilling facility at village level. The results of such integrated

efforts are aimed at sharing with the valued customers of BBDIL and the society at

large.

The layout of the entire factory complex at Aligarh has been designed to have a green belt

around the factory so that the entire atmosphere is dust and pollution free. The total

covered area of the main factory building, including utilities, administration block &

guesthouse (in process), is set up on a picturesque landscape.

The plant houses the State-of-Art Technology both in equipment and manufacturing

processes.

BBDIL has been very closely associated with Westfalia Separators AG, Germany who has

supplied the entire package of equipment for manufacture of Acid Casein.

Lactose Plant and Separators have been procured from pioneers in Dairy Industry like Alfa

Laval.

BBDIL has its entire plant of NF/UF set up on a turnkey basis by APV Invensys



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At the well automated BBDIL, the milk reception and pre-processing is planned to begin

from the keyboard of the computer and carries on through various stages till the final

product has been produced.

The present products being manufactured at BBDIL are Acid Casein, Lactose, Whey

Protein Concentrate, Skimmed Milk Powder & Ghee

Presently the company is concentrating to produce nutritionally superior, hygienically safe

and economically viable products.

On export front company has already created a strong base in US & Europe by exporting

Skimmed Milk Powder and proposes to continue doing so even strongly by taking its other

products like Casein, Lactose & Whey Protein Concentrates to the World Market. Besides

this, the Company is eagerly looking forward and preparing for opportunities to export its

products in the emerging markets in China & Japan. To achieve this ambitious plan the main

agenda will be: PRODUCT SAFETY AND QUALITY.



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1. Scope

1.1 General

Bhole Baba has developed and implemented the Food Safety Management System (FSMS)described in this manual to help us to operate with increased effectiveness, efficiency, consistencyand customer satisfaction. Our QMS utilizes the process approach and quality managementprinciples contained in the international standards ISO 22000 to enhance our ability to continuallyimprove.

1.2 Application

Our FSMS complies with all applicable requirements contained in ISO 22000, covers the

following scope:

Products Processes Site (s)

Skimmed Milk Powder

Casein & Derivatives

Lactose

Whey Protein Concentrates

Ghee

ManufacturingPackaging &Dispatch.

1.3 Organization Structure

Appendix A


List the site address


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2.1 Food Safety policy

We, At Bhole Baba Dairy Industries Limited, Are Committed To

Manufacture & Supply Quality Food Products To

Achieve Customer Satisfaction, Through

Continual Improvements In Products, Processes & Systems.

Our policy statement indicates our commitment and focuses on what is important to us as an

organization: achieving customer satisfaction; and it prescribes the method by which weaccomplish this: by continually improving processes, and services to ensure they consistentlymeet or exceed requirements. Moreover, our policy statement acts as a compass, providing thedirection and a framework for establishing key performance measures and related improvementobjectives.

2.2 Food Safety objectives

Our overall goal is to achieve our Food Safety policy, and maintain the integrity of andcontinually improved FSMS. At the Management level, MRC will monitor and measure

performances in the areas outlined below and, where needed, establish measurable improvementobjectives.

---

---

---

At the operational level, all Staff members will monitor and measure performance of processeswithin their area(s) of responsibility.


Insert the various objectives


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3. Reference Documents (including Statutory and Regulatory requirements)The following external documents contain provisions which, through reference in this manual,constitute provisions of our FSMS:

ISO 22000 Food Safety Management System Requirements for organizations through out thefood chain.Prevention of Food Adulteration Act 1954, Edition 2005IS 10500, IS-14543 Water----Agmark GuidelinesCAC/RCP 57-2004, Code of Hygiene Practice for Milk and Milk ProductsCAC/RCP 56-2004Code of Practice for the Prevention and Reduction of lead Contamination inFoods.

Specify the Registration numbers with various statutory bodies.

4. Control on out-sourced Process:

S.No.

Process Control Mechanism

1. Calibration ISO/IEC 17025 certified LaboratoryNABL Accreditation

5. Food Safety Team:

Sr. Designation Competence Criteria

Skill 1 Skill 2 Skill 3

1 President (Operations)

2 Manager (Quality Control)

3 Manager (QMS) (HACCP Co ordinator)

4 Manager (Production)

5 Manager (Engineering)

6 Sr. Microbiologist

Skill 1: Expertise in different aspects of food safety ranging from farm to fork.

Skill 2: Awareness of the requirements of HACCP

Skill 3: Experience in Food Industry (min. 2 yrs)

6. Appendix:

A Organization Structure


Look out for any moreout sourced product/

List all the statutory requirements.


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B List of Procedures, which define the key processes for implementing our quality policy.Note:Procedure Document Control contains procedures governing the control of these andother FSMS documents.

C Description of compliance to ISO 22000 requirements



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Appendix

Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without prior permission. Offenders will be held liablethe payment of damages.

Organization Chart


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Appendix BList of Procedures

S. No. Description Document No.1. Procedure for document control QS/P/001

2. Procedure for record control QS/P/002

3. Procedure for Audits QS/P/003

4. Procedure for management review meeting QS/P/004

5. Procedure for Identification, Traceability & Recall QS/P/005

6. Procedure for Corrective actions QS/P/0067. Procedure for Preventive actions QS/P/007

8. Procedure for interaction with customers (complaints,feedback)

QS/P/008

9. Procedure for emergency preparedness / contingency QS/P/009

10. HACCP Manual of Raw Milk Reception HACCP/01

11. HACCP Manual of Ghee HACCP/02

12. HACCP Manual of Skim Milk Powder HACCP/03

13. HACCP Manual of Casein HACCP/04

14. HACCP Manual of Whey Processing HACCP/05

15. HACCP Manual of Lactose HACCP/06

16. HACCP Manual of Whey Protein Concentrate HACCP/07

17. Current Good Manufacturing Practices (CGMP)

18. Procedure for Standard Sanitary Operating Procedures(SSOP)

19. Procedures at Engineering Stores STR/ENG/P/001

20. Procedures at Packing Material & Finished Goods Stores STR/PMFG/P/001

21. Procedures for Mechanical Maintenance ENG/MECH/P/001

22. Procedures for Electrical Maintenance ENG/ELE/P/001

23. Procedures for Instrumentation & Control ENG/I&C/P/001

24. Procedure for Human Resource & Personnel RelatedTasks

HR/HR/P/001

25. Procedure for Training HR/TRG/P/001

Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.


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S. No. Description Document No.26. Procedure for Purchase of all material except milk PUR/PUR/P/001

27. Procedure for Purchase of milk PUR/PUR/P/002

28. Procedure for evaluation of suppliers PUR/PUR/P/003



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Appendix CAdequacy Matrix

(FSMS vs. ISO 22000)

CLAUSEOF IS/ISO9001:2001

REQUIREMENTS OF THESTANDARD

SYSTEM DOCUMENTATION

4 Food Safety Managementsystem(title only)

---

4.1 General Requirements FSM-BB-01

4.2

4.2.14.2.24.2.3

DocumentationRequirements(title only)GeneralControl of DocumentsControl of records

---

FSM-BB-01QS/P/001QS/P/002

5 Management Responsibility(titleonly)

---

5.1 Management Commitment FSM-BB-01

5.2 Food Safety Policy FSM-BB-01

5.3 Food Safety ManagementSystem Planning

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5.4 Responsibility and authority HR/JR/P/001-009

5.5 Food Safety Team Leader Mr.

5.6

5.6.1

5.6.2

Communication (Title Only)

External Communication

Internal Communication

---

Subject ResponsibleSuppliers & Contractors Mr.

Customers Mr.(QS/P/008)

Food Authorities Mr.

Other stake holders Mr.

Meetings, Training Programs, Circulars,EPBX, Notice Boards, Work Instructions etc.

5.7 Contingency Preparedness &response

QS/P/009

5.8 Management Review (TitleOnly)

---



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CLAUSE

OF IS/ISO9001:2001

REQUIREMENTS OF THE

STANDARD


5.8.15.8.25.8.3

GeneralReview InputReview Output

QS/P/004

6 Resource Management(title only)

---

6.1 Provision of resources ---

6.26.2.1

Human Resources (title only)General

---HR/HR/P/001

6.2.2 Competence Awareness andTraining

HR/TRG/P/001

6.3 Infrastructure ---

6.4 Work Environment ---

7 Planning & realization of safeproducts (title only)

---

7.1 General ---

7.2

7.2.1

7.2.2

7.2.3

Pre-requisite program(title only)

General requirements

Infrastructure & MaintenancePrograms

Operational PRPs

---

---

ENG/MECH/P/001ENG/ELE/P/001ENG/I&C/P/001

Refer List of PRP

7.3 Preliminary steps to enableHazard Analysis (title only)

---

7.3.1 General ---

7.3.2 Food Safety Team FSM-BB-01

7.3.3 Product Characteristics ---

7.3.3.1 Raw materials, ingredients &

product contact materials

STR/ENG/P/001

STR/PMFG/P/001HACCP/01-07

7.3.3.2 End Product Characteristics HACCP/01-07

7.3.4 Intended Use

7.3.5 Flow Diagrams, process steps &control measures (Title Only)

---

7.3.5.1 Flow Diagrams HACCP/01-07



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CLAUSE

OF IS/ISO9001:2001

REQUIREMENTS OF THE

STANDARD


7.3.5.2 Description of process steps andcontrol measures

HACCP/01-07

7.47.4.17.4.2

7.4.37.4.4

Hazard Analysis (title only)GeneralHazard identification &determination of acceptablelevelsHazard AssessmentIdentification & Assessment of

control measures

---HACCP/01-07

7.5 Design & Redesign of operational PRP

Refer List of PRP

7.6

7.6.17.6.27.6.3

7.6.4

7.6.5

Design & Redesign of HACCPPlan (Title only)HACCP PlanIdentification of CCPsDetermination of critical limitsfor CCPsSystem for the monitoring ofCCPs

Actions when monitoring resultsexceeds critical limits

---

HACCP/01-07

7.7 Updating of preliminaryinformation and documentsspecifying the PRP andHACCP Plan

QS/P/001QS/P/004

7.8 Verification planning Refer the procedure for verification

7.9

7.9.1

Operation of the food safetymanagement system (Title only)General

---

---

7.9.2 Traceability System QS/P/005

7.9.3 Corrections & Correctiveactions (Title only)

---

7.9.3.1 Corrective actions QS/P/006

7.9.3.2 Corrections Refer the procedure for control of NCP

7.9.4 Handling of potentially unsafeproducts

Refer the procedure for control of NCP

7.9.5 Recalls QS/P/005



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CLAUSE

OF IS/ISO9001:2001

REQUIREMENTS OF THE

STANDARD


8 Verification, validation andimprovement of food safetymanagement system (Title only)

---

8.1 General ---

8.2 Monitoring and measuring ENG/I&C/P/001

8.3 Food safety management systemverification (Title only)

---

8.3.1 Internal Audit QS/P/003

8.3.2 Evaluation of individualverification results

Refer the procedure for verification

8.3.3 Analysis of results of verification activities

QS/P/004

8.4 Validation of control measurecombination

HACCP/01-07

8.5 Improvement (Title only) ---

8.5.1 Continual Improvement QS/P/004

8.5.2 Food safety management systemupdating

Refer the procedure for verificationQS/P/001



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