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Ref: SWH Issue 03 Issue Date
‘02/20 Approval Signature
1 of 15
PRIMARY PRODUCTION
HACCP HACCP STUDY
TITLE: HACCP STUDY 1.0 Scope: The aim of the HACCP study is to identify and control all hazards associated with the primary production of peas from field selection to delivery of fresh, raw uncleaned podded peas to a processing factory. Hazards to be considered have been separated into the following groups: Microbiological safety hazards Physical safety hazards Chemical safety hazards 1.1 Microbiological Safety Hazards: Raw peas (by their nature: agricultural crop) could be contaminated with enteric or other soil related pathogens. Peas are removed from the pod in the vining process in the field therefore they are subjected to environmental pathogen contamination from soil, vegetation and contact with agricultural equipment (viners, hi-lift trailers, pea lorries). No steps within the agricultural process are designed to reduce microbial load of the peas delivered to the process factory, microbiological reduction is considered during the cleaning / blanching stages of the pea processing HACCP. There is no microbioligical specification / testing program for peas at the raw material stage. 1.2 Physical Safety Hazards (Foreign Material): Non-vegetable foreign material (e.g. glass, metal, cardboard, plastic, oils, vertebrate animals etc.) 1.3 Chemical Safety Hazards Chemicals or lubricants which in direct contact with the product may be hazardous to health, either by immediate consumption or as the result of cumulative effect. Examples include: Lubricants / Oil / Diesel / Pesticide residues / Heavy metals 1.3.1 Allergens An important chemical hazard is that of allergenic materials, the company is aware of the increased level of allergenic intolerance incidents and as such these hazards have been considered as an integral part of the HACCP. The hazards associated with allergenic reactions are as per The Food Labelling (Amendment) (England) (No.2) Regulations 2004, schedule AA1 (amended) are detailed below: -Cereals containing gluten, wheat, rye, barley, oats, spelt, kamut and their hybridized strains -Crustaceans -Eggs
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PRIMARY PRODUCTION
HACCP HACCP STUDY
-Fish -Peanuts -Soya beans -Milk -The following nuts: Almond (Amygdalus communis L.), Hazelnut (Corylus avellana), Walnut (Juglans regia), Cashew (Anacardium occidentale), Pecan -Celery -Mustard -Sesame Seeds -Sulphur dioxide and sulphites at concentrations of more than 10 mg/kg or 10mg/litre expressed as SO2 -Lupins -Molluscs
Ref: SWH Issue 03 Issue Date
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PRIMARY PRODUCTION
HACCP HACCP STUDY
2 Study Team / Review Team:
NAME AREA OF EXPERTISE HACCP TRAINING
NINA DRURY QUALITY & SYSTEMS RISK ASSESSMENT PROTOCOLS
BSc FOOD SCIENCE CIEH INTERMEDIATE CERTIFICATE IN HAZARD ANAYSIS RSPH LEVEL 3 AWARD IN HACCP
MATTHEW HAYWARD PRIMARY PRODUCTION/ AGRICULTURAL OPERATIONS
CASCADE TRAINING
3 Product Description Product PEAS (vining , processed) Red Tractor Assurance: Fresh produce scheme Category 2 Product Description Fresh immature peas of suitable wrinkled varieties of the plant pisum sativun with organoleptic characteristics of fresh peas. Packaging Bulk product delivered on dedicated pea lorries. Storage Conditions N/A Harvested and transported directly to the processing factory in a timely manner, 150-minute product quality claims are applicable to this product. Product Life N/A Intended Use Raw material only, not intended to be consumed in raw stage, subjected to various washing, grading, blanching and freezing into bulk prior to pack into consumer packs in which the end product is intended to be cooked prior to consumption. Target Groups All Exclusions None
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PRIMARY PRODUCTION
HACCP HACCP STUDY
4 Basic Process Flow 5. Pre-requisite programs
AREA CONTROL MEASURES
SUPPLIER APPROVAL
All growers within Swaythorpe Growers are Farm Assured certified Red Tractor Assurance: Fresh produce scheme Category 2 Approved pesticide lists Field cropping history Pesticide usage records All provided prior to crop release for harvest Pesticide / HM screening as per MRL sampling policy
TRACEBILITY & PRODUCT RECALL
Full traceability program in place from field to freezer including all crop treatments including seed lot number and seed treatment. Annual product recall test 24 / 7 emergency contact
FIELD GMP Fully maintained and hygiened harvest machinery, including seed drills, harvesters, high lift trailers and pea lorries. Data sheets available for all lubricants / oils used in the field / on field machinery. Field nut policy in place.
TRAINING Field personnel full training records to include Crop / harvest hygiene Glass policy Oil / diesel policy Malicious contamination policy
STEP 1 FIELD
SELECTION / ACCEPTANCE
STEP 2 CROP DRILLING
STEP 3 CROP GROWTH
STEP 4 HARVEST
STEP 5 TRANSPORT TO FACTORY
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PRIMARY PRODUCTION
HACCP HACCP STUDY
6. Risk assessment scoring matrix HAZARD SEVERITY The potential of hazard to cause harm will vary in severity dependent of the hazard itself.
Verbal Numeric Description
Catastrophic 5 Likely to result in death Major damage to grower reputation. Permanent removal from Swaythorpe Growers Ltd
Critical 4
Potential for severe injury, major illness. Major damage to grower reputation. Suspension of grower Potential removal from Swaythorpe Growers Ltd
Moderate 3 Potential for moderate injury, lost time illness. Significant damage to grower reputation. Potential suspension from Swaythorpe Growers Ltd
Minor 2 Potential for minor injury
Negligible 1 No significant risk of injury, illness or effect on reputation.
LIKELIHOOD OF OCCURRENCE The likelihood of a hazard occurring should be calculated taking into consideration the specific controls in place relating to the hazard & historical knowledge / data relating to the hazard.
Verbal Numeric Description
Frequent 5 Hazard will occur
Probable 4 Hazard will be experienced
Occasional 3 Some manifestations of the hazard are likely
Remote 2 Manifestations of the hazard are possible but unlikely
Improbable 1 Manifestations of the hazard are unlikely
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PRIMARY PRODUCTION
HACCP HACCP STUDY
HAZARD RISK MATRIX – RISK RATING
FREQ
UEN
CY
5 5 10 15 20 25
4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5
1 2 3 4 5 SEVERITY
Unacceptable risk zone Activity must be prohibited until further controls are introduced to bring the hazard to an acceptable level. Acceptable risk zone Risk is adequately controlled, and no further control is required. Risk as low as reasonably practicable Controls have been put in place to reduce the risk to as low as reasonably practicable.
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PRIMARY PRODUCTION
HACCP HACCP STUDY
7. Critical control point determination
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP
1. FIELD SELECTION
/ACCEPTANCE
C Contaminated land toxic waste / heavy metals / allergenic
materials.
4 1 4 Approved suppliers with Assured Produce certification.
Previous cropping history made available to Swaythorpe Growers as
part of approval process.
Y N Y Y No It is a pre-requisite that full crop history
& soil analysis is provided and assessed by Swaythorpe
Growers.
P Potential for contamination of non-crop material
4 2 8 Field visual inspection carried out with consideration of public
walkways / road ways / laybys in close proximity to the field
Y N Y Y No Field walking Raw material assessment at process plant
Raw material for further processing.
M Pathogenic bacteria from human / animal waste application to
land
4 1 4 Approved suppliers with Assured Produce certification.
Previous cropping history made available to Swaythorpe Growers as
part of approval process.
Y N Y Y No It is a pre-requisite that full crop history
& soil analysis is provided and assessed by Swaythorpe
Growers.
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP
2. CROP DRILLING
C Use of contaminated seed / seed with
unapproved treatments.
Use of contaminated
drill cross contamination with
cereal seed
5 1 5 Seed purchased directed from approved seed breeders.
UK approved seed treatments. Full traceability on seed use /
treatment.
Full hygiene of drill post drilling of cereal crops.
Y N Y Y No Full traceability all applications /
treatments checked prior to harvest
approval.
3. CROP GROWTH
C Use of non-approved pesticides on growing crop
Use of incorrect application rates
5 1 5 Swaythorpe Growers approved pesticide list issued annually to all
growers.
Recommendations made by BASIS trained agronomists whom have access to Swaythorpe Growers
approved pesticide list.
Application of pesticides by NRoSO equipment/operators (National
Register of Spray Operators)
Y N Y Y No All pesticide applications are
subject to audit by BASIS certified
personnel prior to field release for
harvest.
Crops with unapproved
pesticides will not be harvested.
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP 4.
HARVEST C Unapproved
pesticides
Incorrect application rate
Harvest Interval not
elapsed
Allergenic material Crop Incidental continuation via lubricants Incidental contamination from harvest team
5 1 5 Swaythorpe Growers approved pesticide list issued annually to all
growers.
Recommendations made by BASIS trained agronomists
Application of pesticides by NRoSO
equipment/operators (nation register of spray operators)
All pesticide applications are subject to audit by BASIS certified personnel prior
to field release for harvest
Crops with unapproved pesticides will not be harvested.
Harvest approval copied to processing factory unapproved loads will not be
processed. Oil / lubricant contamination policy in
place Nut policy in place.
Y Y - N YES All pesticide applications are
subject to audit by BASIS certified
personnel prior to field release for
harvest.
Crops with unapproved PPP’s
will not be harvested.
Harvest approval required by the factory prior to
processing peas.
Annual MRL analysis carried out.
Historical data available
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP
4. HARVEST
(continued)
P Contamination with non-crop-based
material
3 2 6 Regular field walking / additional inspection carried out where public
walkways / road ways / laybys in close proximity to the field
Pre-requisite controls:
Regular maintenance / daily hygiene inspection of harvesting equipment Field personnel are trained in good harvest practice / contamination / malicious contamination policies.
Y N N NO Raw material assessment at
processing facility
Product cleaning stages and further assessment post
cleaning
Feedback from factory on potential field contamination
Pre-requisite control
C Hydraulic Oil / diesel contamination
4 2 8 Pre-requisite control All harvest personnel signed off on oil / diesel contamination policies including safe refueling away from
crop and clean up / reporting procedures.
Y N N NO Pre-requisite controls in place.
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP
4. HARVEST
(continued)
M Contamination from harvest machinery /
crop residue
1 3 3 Pre-requisite control All field personnel sign off on harvest hygiene procedures.
Y N N NO Pre-requisite controls in place.
Raw material
undergo washing and microbial reduction via
blanching during processing stages.
5. TRANSPORT
M Contamination from lorry body / crop
residue
1 3 3 Pre-requisite control All field personnel sign off on harvest hygiene procedures.
All vehicles undergo pre-use
inspection including previous use, pre-use hygiene.
Y N N NO Pre-requisite controls in place.
Raw material
undergo washing and microbial reduction via
blanching during processing stages.
Lorry bodies rinsed out as part of the tipping process at
the factory
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PRIMARY PRODUCTION HACCP HACCP STUDY
STEP HAZARD
RISK CONTROL MEASURES
DECISION TREE QUESTIONS
JUSTIFICATION
TYPE DETAIL S L RR 1 2 3 4 CCP
5. TRANSPORT (continued)
P
Non crop contamination
during transportation
3 1 3 Pre-requisite control All loads are fully covered with load covers until arrival at the processing factory
Y N N NO Pre-requisite control
Raw material assessment at
processing facility
Product cleaning stages and further assessment post
cleaning
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PRIMARY PRODUCTION HACCP HACCP STUDY
8. PRODUCT SAFETY SCHEDULE
CCP STEP
HAZARD CONTROL CRITICAL LIMIT
MONITORING PROCEDURE
CORRECTIVE ACTION
RESPONSIBILITY RECORDS
1
Harvest
Pesticide Residues in
harvested crop
Harvest interval obeyed
Approval to
harvest
Approval to process
Nil in product Pesticide application records
Routine pesticide
analysis
Destroy harvested
crop
Swaythorpe Growers
YG
Technical manager
Pesticide application
records
Residue analysis results.
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PRIMARY PRODUCTION HACCP
HACCP STUDY
9.QUALITY PLAN
TIMESCALE STEP RECORDS
1.
FIELD SELECTION / ACCEPTANCE
HISTORICAL FIELD DATA
SOIL ANALYSIS APPLICATION RECORDS
2.
CROP DRILLING
SEED PURCHASE RECORDS
SEED TRACEABILITY CROP PLAN
CONTINUITY PLANNING
3.
CROP GROWTH
CROP INSPECTION CHEMICAL RECOMMENDATION
CHEMICAL APPLICATION ADVANCE SAMPLING
FIELD WALKING
4.
HARVEST CCP 1
FIELD WALKING HARVEST APPROVAL HYGIENE CHECKLIST
LOAD TICKET 150 MINUTE START TIME
TRANSPORT TO FACTORY
COMPLETED TICKET
16
WEEKS
HI
< 2 HRS