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 0c - 25

0c

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


Ingredient List

Product: Honey

Code:

Ingredients (descending order of predominance by weight):

Pure Honey

Reviewed By: Date: .

4

Company Form # HA-1IN


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


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


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


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 Handlers 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 handlers 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


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


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


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


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


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


Matter accumulated

during processing,

insect parts

Low

Low

No

A clean white cloth used to strain Honey

before bottling.

No

14

Bottling / capping


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 asCritical 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


Sanitizing residue.

Physical -Particles, insect

pieces, soil, wire,

Plastic and metal.

No

Yes

No

Yes

Yes


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


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


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


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


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


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


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


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.

26

Company Form # HC-1


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:

Documents

Rajkumar Honey HACCP Plan