HACCP Manual for jam industry

HACCP Analysis for the Pineapple Jam
Freshtz Products Page 1
1.0 Introduction
1.1 About the establishment
“Freshtz” which is located in Industrial Zone, Ja-ela, Sri lanka, is an establishment
that produce Pineapple jam in order to serve nutritive, good quality and safe fruit products to
the nation. It was established in year 2000 with the collaboration of few people. The
establishment is now a large scale plant which is functioning with 400 employees including
to management. Though the company is in its initial stage, it has a considerable acceptance
by the local customers and now it has been extended to overseas customers. Since the
company has developed a good trade name among customers, the management of the
establishment wants to implement HACCP plan and get the certification to assure the safety
of the product and for further improvement of the market share.
Currently, “Freshtz” is targeting specially the adult and younger population of all
around the country. The products are available in almost all retail shops and super markets,
which are easily accessible to the target population. The company is planning to introduce a
wide range of modified products such as sugar free Jam products targeting the other
population groups, in near future.
Raw materials are received from selected, qualified suppliers in North Western
province. The company has its own standards in purchasing process and especially the most
important raw material; pineapple is purchased from reputed suppliers. The process flow and
the plant are designed according to the international standards to avoid cross contamination
and assure the maximum quality of the end product. The establishment is currently following
Good Manufacturing Practices (GMPs) and written Sanitation Standard Operation Procedures
(SSOPs) as pre-requisites for implementing HACCP. The final products are distributed
throughout the country, via a distribution company which is qualified with required
standards.
1.2 Vision
To be a pioneer nutritive, safe and high quality, Jam producer in Sri Lanka.
1.3 Mission
Serve the local suppliers and our customers through engaging in reasonable business and
providing high quality product.

2.0 Hazard Analysis Critical Control Point (HACCP)
Hazard Analysis and Critical Control Point (HACCP) is an internationally recognized
system for reducing the risk of safety hazards in food.Implementing a HACCP System
requires that both Prerequisite Programs and HACCP Plans are implemented.
Prerequisite programs are programs that are put in place in the facility to control hazards in
the environment, preventing contamination of the product. Prerequisite programs ensure a
hygienic environment and good manufacturing processes for personnel that reduce the risk of
contamination of the food product.
HACCP Plans are prepared for each process or product, and identify possible hazards and
controls in place to make sure the hazards are eliminated or controlled to ensure acceptable
levels in the food. Awareness of food-borne illness is increasing and concern throughout the
industry is driving the use of HACCP and HACCP based certification programs.
 Global market place
 Increasing incidents of food-borne pathogens
 New pathogens emerging
 Need to protect Brands, control risks
A typical approach to implementing the 7 basic principles would be:
A risk assessment should be done during which risk and hazard categories should be
established. And then elimination of hazards should be done by design if possible. Then it
should be controlled of hazards that cannot be eliminated by an associated Critical Control
Point Definition of the control, monitoring, reporting and action procedures for each CCP.
Revision of manufacturing process flow diagrams should be done and finished product
quality specifications to encompass HACCP. Then a formal review of HACCP whenever
processes are done or product specifications are modified.
When determine the critical control point a decision table has been used to determine when a
Critical Control Point (CCP) is necessary. A ‘Yes’ answer to two key questions defines a
process step as a CCP.
It is important to consider about the process of jam production. It consists with these
main steps. Also it is important to pay attention to the input used in the particular step,
possible hazards and there are several questions which are involved in CCP determination.
Q1. Do preventive measures exist at this step for the identified hazard? If the answer is
yes, should move to the next question and if the answer is no there is another question which
is referred is control at this step necessary for safety? If the answer is yes for this question,
modify step, process or product and return to the Q1. If the answer is no, there is no CCP.
Q2. Does this step eliminate the hazard or reduce the likelihood of its occurrence to an
acceptable level? If the answer is no should move to the next question and if the answer is
yes, this is a CCP.
Q3. Could contamination with the identified hazard occur in excess of acceptable levels
or increase to unacceptable levels? If the answer is no this is not a CCP. But if the answer is
yes, should move to the next question.
Q4.will a subsequent step eliminates the hazard or reduces the likelihood of its
occurrence to an acceptable level? If the answer is no this is a CCP. If the answer is yes,
this is not a CCP. After that can determine the CCP number the processes have.
In our establishment different posts have different tasks which are support to maintain
the production and quality of the products. There are several sections in the company known

as receiving area, processing and production area, packaging area, distribution section. The
members of the staff including executive manager, quality assurance manager, production
managers, supervisors, team leaders, workers etc, are having different roles throughout the
process.
There are number of major benefits to be gained from implementing an HACCP
approach in “Freshtz”. They include, HACCP is a management tool that provides a more
structured approach to the control of identified hazards than traditional inspection and quality
control procedures. HACCP can identify potential problems where failure has not yet been
experienced. Control of process and product quality is transferred from detection of failure to
prevention. In some circumstances this can bring about a significant improvement in
profitability by reducing product losses and reworks and exposure to liability. Also HACCP
is especially useful when designing new products and processes. HACCP can be useful in
obtaining existing quality standards (e.g. ISO9000) and covers all aspects of product safety. It
is also an internationally accepted approach to quality assurance and an important aspect of
the defense of due diligence. It provides a cost-effective control of hazards and properly
implemented focuses the attention of all involved in a process on critical areas.
3.0 Pre requisite programs
There are some basic practices that should be applied before implementing the
HACCP program in “Freshtz” and these are applied in following areas
3.1 Receiving and storage
Raw materials can be considered as major source of contamination. It is essential that
critical evaluation of procedures for raw material receiving and handling. For storage re-
evaluate the requirements and effectiveness of rooms and equipment for temperature control
and other environmental requirements (e.g. humidity) as appropriate. Check the potential for
overhead contamination and contamination from outside the facility, and effectiveness of
preventative measures.
3.2 Sanitation of premises and surrounding environment
Every attempt should be made to minimize contamination sources in the exterior
surroundings of the facility.
Sanitary facilities, wash rooms, and toilets should be separated from process areas and
should be clean and maintained. Employee hand washing sinks with water should be
provided and accessible to work areas.
Since Cleaning and sanitization procedures are the most important tasks in a food
processing/handling operation. Standard chemical supply for sanitation in company is useful
for effective cleaning and sanitizing program. Inspection and documentation can increase the
effectiveness of cleaning and sanitizing at regular intervals & selection and identify reliable
persons to be responsible for such operations.
3.3 Personal hygiene of employees
Evaluate the effectiveness of employee training programs with regard to personal
hygiene and sanitary practices. An increasingly common source of contamination in food
processing and handling is poor hygiene practices by employees. All employees should be

instructed as to the importance of proper hygiene reminders or signs can help. Assess
employee working patterns Control access to critical areas for both visitors and employees.
3.4 Water supply
A food processing and handling facility should be provided with potable water. Water
from private wells should be sampled and examined for safety through microbiological
analysis on a regular frequency.
3.5 Lighting and ventilation
Evaluate the adequacy of lighting in the facility. If employees do not have adequate
lighting, they cannot effectively operate, maintain, and clean equipment. A poorly ventilated
plant will have condensation problems which increase the risk of overhead contamination.
3.6 Equipment handling and maintenance
Evaluate all for general sanitary design and construction. Cleanable grade stainless
steel surfaces are recommended wherever possible. Generally, wood surfaces are not
considered cleanable in design. Care should also be used in evaluating aluminum surfaces.
Aluminum can become corroded, cracked, and pitted with long term exposure to chemicals or
corrosive food materials. Corroded aluminum is not cleanable.
3.7 Waste management
Waste facilities should be separated from processing/handling areas and be cleaned
and maintained on a regular basis so as not to attract pests. Keep garbage and trash containers
or bags covered and sealed.
3.8 Pest control
Consult with a reputable pest control company to assist in pest elimination in the
processing environment. A designated, reliable employee should be charged with
responsibility to monitor and document the effectiveness of such a program.
For pest controlling, keep all entrances closed, remove stagnant water, control weeds
in the surroundings, check the perimeter of the facility for cracks or holes, be sure all food
products and packaging materials are stored on pallets off the floor, dispose of trash and
waste at the end of every work day, and monitor any other appropriate activities to control
pests.

4.0 Introduction about HACCP forms
When a HACCP plan is developed for a product, it has a procedure to continue
consequently. According to that, there are eight forms to fulfill in HACCP plan development
process. Those forms are very important to fill correctly to develop a good quality HACCP
plan for a product as well as to get standard good quality product finally. The HACCP forms
are, product description form, ingredients & incoming material list form, indented use and
consumers form, plant schematic form, hazard analysis & preventive measures form, CCP
determination form, critical limits, monitoring & corrective action form and verification &
record keeping form.
First form is used to describe about the jam product. Mainly, this form includes
product name, important product characteristics (like pH, water activity), about product
usage, packaging, shelf life, labeling instruction and special distribution control (store under
10o
C).
Second form provides a list of ingredients and incoming materials which are needed
to produce final product.
Third form is important to get idea about the target people of the product. That mean,
provide details about who are the people this product is buy mainly or who are the main
consumers of the product.
Forth form is displayed mainly jam production flow chart and specific condition of
some steps. All processing steps and their specific condition and as well as all ingredients &
incoming materials are included in the processing flow chart of jam and they are connected
with each other steps. In addition, the flow diagram can include steps in the food chain
which are before and after the processing that occurs in the establishment. The flow diagram
need not be as complex as engineering drawings. The purpose of a flow diagram is to provide
a clear, simple outline of the steps involved in the process.
The fifth form is used to analyze the hazard and apply to preventive measures for that
hazard condition of jam production. The purpose of the hazard analysis is to develop a list of
hazards which are of such significance that they are reasonably likely to cause injury or
illness, if not effectively controlled. All the ingredients and processing steps should be
included for that analysis procedure. The hazard analysis is the key to preparing an effective
HACCP plan. If the hazard analysis is not done correctly and the hazards warranting control
within the HACCP system are not identified, the plan will not be effective regardless of how
well it is followed. A hazard is defined as a biological, chemical and physical agent that is
reasonably likely to cause illness or injury in the absence of its control. In this form, if an
ingredient or processing step is become a hazard, check whether there is a preventive method
or control method for that and if there is preventive method, it can be applied to control it to
acceptable level.

The sixth form is used to determine the critical control point from the all ingredients
and processing steps. Complete and accurate identification of CCPs is fundamental to
controlling food safety hazards. Although application of the CCP decision tree can be useful
in determining if a particular step is a CCP for a previously identified hazard.CCPs must be
carefully developed and documented. In addition, they must be used only for purposes of
product safety. For example, a specified heat process, at a given time and temperature
designed to destroy a specific microbiological pathogen, could be a CCP.
The seventh form is used to identify critical limits, monitoring procedure and
corrective action of CCPs. All CCPs are used in this form to maintain desired level. A critical
limit is a maximum and/or minimum value to which a biological, chemical or physical
parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level
the occurrence of a food safety hazard. Critical limits may be based upon factors such as:
temperature, time, moisture level, water activity (aw), pH, sensory information such as aroma
and visual appearance. Monitoring is a planned sequence of observations or measurements to
assess whether a CCP is under control and to produce an accurate record for future use in
verification. An important purpose of corrective actions is to prevent foods which may be
hazardous from reaching consumers. Where there is a deviation from established critical
limits, corrective actions are necessary.
The last form is used to verification and record keeping. Verification is defined as
those activities, other than monitoring, that determine the validity of the HACCP plan and
that the system is operating according to the plan. These processes should take place during
the development and implementation of the HACCP plans and maintenance of the HACCP
system. All forms should be approved by relevant person to check whether that procedure is
done correctly.
5.0 Preliminary steps
It is important to ensure that a HACCP plan has a solid foundation and that safe food
is produced, certain initial steps must be carefully followed. It is extremely important to have
full commitment to the HACCP initiative from management at all levels. Without a firm
commitment, it may be difficult or impossible to implement the HACCP plan. Before the
study is begun, management should inform all staff of the intention to implement HACCP.
Both the company and the personnel involved in the development of the HACCP plan must
be totally committed to its implementation.
Preliminary steps are designed to produce safe product through the well established
HACCP procedure. There are five preliminary steps should be followed initiating the
HACCP plan for pineapple jam production.

5.1 Steps 01 - Assemble HACCP team
The purpose of the HACCP Team is to ensure safe products for our customers and
their consumers. The HACCP Team will evaluate raw materials and processes to determine
Critical Control Points those points will be monitored as will other points and processes.
The HACCP team will provide documented training for the members of firm & HACCP Plan
will be re-assessed at least annually.
HACCP TEAM
Factory Name:- “Freshtz” Product (pvt) Ltd.
Team Member Name Position HACCP Team Role
E.M.P.P. Ekanayaka Production
Executive
Coordinator
T.S.M Thilakarathne Quality Executive Member
N.R Nanayakkara Marketing &
Finance Executive
Member
T.Gawshiga Engineer Member
W.M.K.I.Bandara Fruit reception
manager
Member
Barathy Muddiyappu Shift leader of
cutting, washing &
peeling
Member
Chageethana Shift leader of
production &
packaging
Member
Shashindhi Samarakoon Cleaning supervisor Member
Thadshayani SLSI consultant Advisor
Pabodha Kodagoda Labour Member
Approved by:-…………………………. Date:-…………………………

5. 2 Step 02 –Product details & its distribution
Full descriptions of the pineapple jam including ingredients, processing methods &
safety information is mentioned in second preliminary step.
Form #01Product Description
1. Product name Pineapple jam
2. Important product characteristics aw= 0.85
pH = 3.2~3.4
color = yellow
sugar = 60%
jam = 68% brix
fruit pulp = 25% brix
Ingredients
 Pineapple
 Sugar
 Pectin
 Citric acid
 Sunset yellow
 Water
3. How is product used With bakery products as spread
4.Packaging  In sterilized glass jars with air tight, non
corrosive lids
 1 dozen of jam jars are packed in
compartmentalized corrugated boxes.
5. Shelf life Unopened (room temp) = 8 months
Opened (in refrigerator ) = 8 months
6. Where will product be sold Super markets
Retail shops
7. Labeling instructions 1. Name of the product
2. Manufacturer’s name
3. Manufacturer’s registration number
4. Manufacturer’s address
5. Batch number
6. Ingredients
7. Storage conditions
8. Manufactured date
9. Expiry date
10. Nutritional composition
11. Price
12. Company logo

8. Special distribution control  Store under ambient conditions
 Handle with care
 Maximum No of 6 boxes can be stored
on top of each other
Date:-.……………. Approved By: - …………
Form# 02List Ingredients & Incoming Material
Process/Product Name(s): Pineapple jam
Pineapple (Fresh, Ripened) Chlorine
Sugar Glass bottles
Pectin Popup lids
Sunset yellow (E110) Ink
Citric acid Labels
Well Water Glue
Corrugated boxes
Date:.……………. Approved By: ….. …………

5.3 Step 03 – Intended use & consumers
The consumer target group was identified for HACCP study.By identifying the target
group; it will help the HACCP team to determine hazards that may become significant for
vulnerable consumers.
Form #03 Indented use & consumers
Product Name(s): Pineapple jam
 General consumer – All age groups except children less than 5 years
 Food industry – Hotels, Fast food outlets
 Not recommended for the people with diabetics
Date:-……………. Approved By:-….. …………
5.4 Step 04 – Flow diagram for pineapple jams production
Flow diagram with clear simple outline was developed describing all steps of pineapple jam
production
5.5 Step 05 – Verification of flow diagram Form # 4
Upon completion of the process flow diagram, members of the HACCP team visited
the manufacturing area to compare what information is present on the process flow diagram
compared to what actually happens during production.

Receiving Receiving
Pumping &
Sand filtering Receiving Receiving Receiving Receiving Receiving Receiving Receiving Receiving Receiving Receiving
WeighingWeighingWeighingWeighing Weighing
Washing &
Sorting
Peeling
Cutting
Crushing
Weighing
Filtering
Heating
Heating & Mixing
Pasteurization ( 72
0
C/20 sec )
Filling & Sealing
Cooling
Labeling & label printing
Packing
Transporting
Visual Observation
Storage 01 Storage 02 Storage 03 Storage 04 Storage Storage Storage 07 Storage 08 Storage 09 Storage 10 Storage 11 Storage 12 Storage 13
Fruit processor
Pulp Storage
Cl2MixtureMicro Filter
Storage 14
Ingredient Mixture
Jam Mixture
Pineapple Jam
Storage 15
Bottle Sterilizer
Bottle Filler &
Sealer
Pineapple Jam Bottles
Bottle labeler &
Printer
Labeled Jam Bottles
Pineapple Well water Chlorine Pectin Sugar Citric acid E 110 Glass Bottles Popup lids Ink Labels Glue Corrugated boxes
Two dozen jam cartons Storage 16
Wastes
Municipal
Waste
Management
System
Date:-.……………. Approved By:-….. …………

6.0 Hazards Analysis and Preventive Measures (Form #5)
Ingredient/
Process step
Potential Hazards Introduced,
Controlled or Enhanced at this
Step
B = Biological; C = Chemical;
P =Physical
Is Hazard Likely
to Occur &
Sever Enough to
Warrant
Control (Yes/No)
Justification for Decision What control Measures Can Be
Applied Prevent , Eliminate, or
Reduce to Acceptable Levels
Receiving
fresh
pineapple
B- Salmonella spp. Yes Damage fruits can also be come
together with fresh fruits.
When the fruit is sorted, damaged
and spoiled fruit are removed and
the selected fruit also cleaned.
This Microorganism cannot
survive in final products ph range
of 3.2~3.4
E. coli Yes Damage fruits can also be come
of 3.2~3.4
Clostridium perfringens, Yes Damage fruits can also be come
Staphylococcus aureus, Yes Damage fruits can also be come
together with fresh fruits
the selected fruit also cleaned
of 3.2~3.4

Vibrio cholerae Yes Damage fruits can also be come
together with fresh fruits
the selected fruit also cleaned
Yeast & Mold No In case of overdose herbicidal
usage
C: Herbicide Yes In case of overdose fertilizer usage Fruit is obtained from trusted
(recorded)
Nitrate Yes In case of overdose fertilizer usage Fruit is obtained from trusted
(recorded)
When the fruit is washed nitrates
will washed away with water.
P- Wood No Not available in cleared
commercial pineapple cultivation
lands
Sand Yes Normally pineapple is grown closer
to the ground layer.
When the fruit is washed wood
and sand will washed away with
water.
Pineapple
temporally
storage
B-No No
C-No No
P-No No
Receiving
citric acid
B- No No Citric acid is obtained from trusted
supplier.
C- No No Citric acid is obtained from trusted
supplier.
P- No No Citric acid is obtained from trusted
supplier.
Citric acid
storage
B- No No
P- No No
C- No No
Receiving
sugar
B- No No Sugar is obtained from trusted
supplier.

C- No No Sugar is obtained from trusted
supplier.
P- No No Sugar is obtained from trusted
supplier.
Sugar storage B- No No
P- No No
C- No No
Receiving
pectin
B- No No Pectin is obtained from trusted
supplier.
C-No No Pectin is obtained from trusted
supplier.
P-No No Pectin is obtained from trusted
supplier.
Pectin storage B- No No
C- No No
P- No No
Receiving
Sunset
yellow(E110)
B-No No E110 is obtained from trusted
supplier.
C-No No E110 is obtained from trusted
supplier.
P-No No E110 is obtained from trusted
supplier.
Sunset
yellow(E110)
storage
B- No No
C- No No
P- No No
Receiving
glass bottle
B-No No Glass bottles are obtained from
trusted supplier.
C- No No Glass bottles are obtained from
trusted supplier.

P- Airborne dust No It would be removed in washing
step
Glass bottle
storage
B- No No
C- No No
P-Broken glass particles Yes Will be damaged during storage Removed from visual observation
Sterilization
of glass
bottles
B-No No
C-No No
P- Glass particles yes Bottle broken down during
handling
Through visual observation
Receiving
Non
corrosive
popup lid
B-No No Lids are obtained from trusted
supplier.
C-No No Lids are obtained from trusted
supplier.
P- Airborne dust No It would be removed in washing
step
Non
corrosive
popup lid
storage
B-No No
P-No No
C-No No
Receiving Ink B-No No
C-Heavy metals Hg, Cr Yes Ink contains heavy metals which
are toxic.
Jam filling and bottle labeling are
done separately.
P-No No
Ink storage B- No No

P- No No
C- No No
Receiving
Glue
B-No No
C- polyurethane resin No Jam filling and bottle labeling are
done separately.
P-No No
Glue storage B- No No
C- No No
P- No No
Receiving
labels
B-No No
c-No No
P-No No
Label storage B- No No
C- No No
P- No No
Receiving
corrugated
boxes
B- No No
C- No No
P- No No
Corrugated
boxes storage
B- No No
C- No No
P- No No
Filtration B- Salmonella sp Yes Salmonella spp cannot filter out
though 1mm mesh
Eliminated by chlorination and
micro filtration steps.

of 3.2~3.4
Vibrio cholerae Yes Vibrio cholera cannot filter out
though 1mm mesh
of 3.2~3.4
C-No No
P-Sand, Stones. Leaves Yes Processing machines can be
damaged
1mm pore sized mesh filter is
used.
Water
primary
storage
B- Salmonella spp Yes Salmonella spp can multiply during
primary storage due to favorable
conditions
of 3.2~3.4
Vibrio cholerae Yes Vibrio cholera cannot filter out
though 1mm mesh
of 3.2~3.4
C- No No
P-No No
Receiving
chlorine
powder
B-No No Chlorine powder is obtained from
trusted supplier.
C- No No Chlorine powder is obtained from
trusted supplier.
P-No No Chlorine powder is obtained from
trusted supplier.
Chlorine
storage
B-No No
P- No No
C- No No

Chlorination B-No No
P-No No
C-Excess chlorine No No use in jam processing steps.
Chlorinated
water storage
B-No No
C-No No
P-No No
Micro
Filtration
B- Salmonella Yes Can cause salmonellosis and
diarrhea
Use pore sizes range from 0.0001
µm to 0.001 µm
Vibrio cholerae Yes Can cause cholera and diarrhea Use pore sizes range from 0.0001
µm to 0.001 µm
P-No No
C-No No
Washing B-No No
C-Herbicides No Remaining herbicides are washed
away with water
Nitrates No Nitrates washed away with water
P-Sand No Sand particles are washed away
with water
Sorting B-No No
C-No No
P- Rotten fruits No All rotten fruits are rejected away
by visual observation
Peeling B- No No
C- Lubricant Yes Contaminations can be occurring
from automated peeler used.
Preventive Maintenance, Use
Food Grade Lubricant

P- Metal fragments
contamination
Yes Contaminations can be occurring
from automated peeler used.
Preventive Maintenance,
Run the product through a filter
Cutting B- No No
C- Lubricant contamination Yes Contaminations can be occurring
from automated trimmer used.
P- Metal fragments
contamination
from automated trimmer used.
Crushing B- No No
from automated crusher used.
P- Metal fragments
contamination
Weighing B-No No
P- No No
C- Over weighing ingredients No Continuously monitoring by staff
Heating B-No No
P- No No
C- No No
Mixing B-No No
Preventive Maintenance, Check
Lubricant Contamination
P- Metal fragments
contamination
Bottle filling B-No No
C-No No
P-Glass particles Yes Bottles can be damaged on Removed from visual observation

conveyors
Sealing B- No No
C-No No
P- No No
Pasteurization B- Clostridium perfringens, Yes Due to improper time temperature
combinations of pasteurizer.
Continually monitoring the
pasteurizer meter readings.
C-No No
P-No No
Cooling B-No No
C-No No
P-No No
Labeling B-No No
C-No No
P-No No
Printing B-No No
C-Heavy metals in ink Hg, Cr Yes Ink contains heavy metals which
are toxic.
Jam filling and bottle labeling are
done separately.
P-No No
Packaging B- No No
C- No No
P- No No
Final Storage B- No No
C- No No
P- No No
Date: ___________ Approved by:_________________

7.0 CCP Determination Form # 6
Ingredients
/process step
Hazard Q1. Do
preventive
measures
exist at
this step
for the
identified
hazard?
Q2. Does this
step eliminate
the hazard or
reduce the
likelihood of its
occurrence to
an acceptable
level?
Q3. Could
contamination
with the identified
hazard occur in
excess of
acceptable level or
increased to
unacceptable
level?
Q4. Will a subsequent
step eliminate the
hazard or reduce the
likelihood of its
occurrence to an
acceptable level?
CCP
Receiving
fresh
pineapple
Salmonella spp Yes No Yes Yes No
E. coli Yes No Yes Yes No
Clostridium
perfringens,
Yes No Yes Yes No
Staphylococcus
aureus,
Yes No Yes Yes No
Vibrio cholerae Yes No Yes Yes No
Herbicide No No No No No
Nitrate Yes No Yes Yes No
Receiving
Glass bottle
Beads Yes Yes No No No
Glass bottle
storage
Broken glass
particles
Yes Yes Yes No No

Ink
Heavy metals
Hg, Cr
Yes Yes No No No
Sterilization of
glass bottles
Glass particles Yes Yes Yes No CCP # 1 (P)
Well water B- E.coli Yes No No No No
Filtration Sand, Stones.
Leaves
Yes Yes No No No
Micro
filtration
Salmonella Yes Yes Yes No No
Vibrio cholerae Yes Yes Yes No No
Peeling
Lubricant No No No No No
Metal
fragments
contamination
Yes Yes No No No
Cutting
Lubricant
contamination
No No No No No
Metal
fragments
contamination
Yes Yes No No No
Crushing
Lubricant
contamination
No No No No No
Metal
fragments
contamination
Yes Yes No No No
Mixing
Lubricant
contamination
Yes Yes No No No
Metal
fragments
contamination
Yes Yes No No No

Pasteurization Clostridium
perfringens
Yes Yes Yes No CCP # 2 (B)
Filtering Metal
fragments
contamination
Yes No No No No
Printing Heavy metals
in ink Hg, Cr
No No No No No
Bottle filling Glass particles Yes No No No No
Date:___________ Approved by:_________________

8.0 Critical Limits, Monitoring & Corrective Actions Form # 7
Process/Step
CCP
Hazard(s) Critical
Limit
Monitoring Procedure Corrective
ActionsWhat How Frequency Who
CCP # 1
Sterilization of
glass bottles (P)
Broken Glass
particles
No damaged
bottles
Damaged
bottles
Visual
observation
Every bottle Worker at
Sterilization
machine
Remove the
damaged bottle
and send to the
glass recycling
CCP # 2
Pasteurization
(B)
Clostridium
perfringens
0cfu/ml
Clostridium
perfringens
Pasteurization
time and
temperature
Visual
observation
Once the alarm
of the machine
sounds
Worker at
Pasteurization
machine
Hold the
pasteurization.
Call the quality
assurance
executive.
Date:-___________ Approved by:_________________

9.0 Verification and Record Keeping Form # 8
Process Step/CCP Verification Procedure Records
CCP# 1
Sterilization of glass bottles
(P)
Check the machine operation
log every day
comments on log book
CCP # 2
Pasteurization (B)
Check the machine operation
log every day
comments on log book
Date:-………………….. Approved by:-………………..

Appendix
Appendix 1
Hand washing
Proper hand washing must be done by all employees in following situations.
 When starting work
 After break time
 After lunch
 After using the washroom
 After blowing nose
 After handling garbage, after touching a pallet, skid, floor mat or picking up product
from the floor
 Whenever hands have become contaminated
At all time, food employees must be used the following cleaning procedure in the order stated to
clean their hands and exposed portions of their arms.
 First, hands are rinsed under clean, running warm water, which in about 100 0
F for 20
seconds
 Then, the hands are washed using soap for a 10 seconds and nail brush is used to remove dirt
from nails.
 Then, fingers are washed thoroughly.
 Finally, hands are dried from separate towels or a mechanical hot dryer.
 For this purpose should be used only the area which design to the hand washing purpose two
minimize the contaminations.

Standard operation Procedure (SOP)
Item/Description
Object/Area: Pineapple Location- Receiving area
Pre operational sanitation
Responsible party Receiving Supervisor
Name(s) of chemical(s), cleaning products
used and condition (specification for) use
None
Procedure Check the color, size and required maturity
condition of pineapples.
Frequency/Timing Every Batch
Operational sanitation
Responsible party Worker
None
Procedure Check all pineapple and remove damaged
and rotten ones.
Frequency/Timing Every pineapple
SOP creation date: Approved by:
Last update: Updated by:
Item/Description
Object/Area: well water Location
Pre operational sanitation Filtration1
Responsible party Responsible person for water filtration
None
Procedure Filter water using 1mm pore size filter
Removing the physical hazards like sand
,stone, leaves
Frequency/Timing
Responsible party
None
Procedure Filter water using filter(pore size rang
from0.0001µm-0.001µm)
Frequency/Timing

Item/Description
Object/Area: Citric acid Location: Receiving area
Responsible party Store keeper
Procedure Confirm vendor name ,date and time of
delivery
Check the integrity of food packaging
Check the expiry date
Check the compliance of supplier’s
specification with company’s specification
Frequency/Timing Every batch
Responsible party
Procedure
Frequency/Timing
Item/Description
Object/Area: Popup lids Location: Receiving area
Responsible party
None
Procedure Visual observation
check the compliance of supplier’s
specification with the company specification
None
Procedure Washing with sterilized water

Item/Description
Object/Area: Pop up lids Location: cleaning area
Responsible party Responsible person for cleaning
Name(s) of chemical(s), cleaning products used
and condition (specification for) use
Chlorine(5-10ppm)sanitizer
Procedure Visual observation
Checking whether there is any damage in
lids
Adding and mixing chlorine with water
Adding chlorine in to sanitizer machine
Putting the pop up lids in to sanitizer
machine and washing them well
Frequency/Timing Whenever cleaning and for 5 minutes
Responsible party Person responsible for washing and lid
sterilization
None
Procedure Washing with water
Frequency/Timing 5 minutes
Frequency/Timing Each and every lid when comes to packing
Item/Description
Object/Area: glass bottles Location: Receiving area
Responsible party labour
None
Procedure  visual observation
 checking whether there is any
breakages in bottles
 reject the broken glass bottles
None

Frequency/Timing after receiving and until jam is ready to be
filled
Item/Description
Object/Area: glass bottles Location: cleaning area
Responsible party labour
chlorine(5-10ppm) bottle sanitizer
 checking whether there is any
breakages in bottles
 reject the broken glass bottles
 adding and mixing of chlorine with
water
 adding chlorine into bottle sterilizer
machine
 putting the bottles into bottle sterilizer
and washing them well
Frequency/Timing whenever cleaning and for 10 minutes
Responsible party labour responsible for washing and bottle
sterilizer
None
Frequency/Timing 10 minutes
Item/Description
Object/Area: Ink Location: Receiving area
Responsible party Stockeeper
None

 checking the certification of supplier
 rejecting the bottles with leakage
Responsible party whenever receiving
None
Procedure storing in protected area without leakage of
bottles
Frequency/Timing after receiving and until label is ready to
printed
Item/Description
Object/Area: Pine apple Location: processing area
Responsible party Technician or machine operator, and staff
Chlorine water under hot water condition
(72o
C, 10minutes)
Procedure  Wash the machine using normal
water,
 Then wash the machine with
chlorinated hot water for 10 minutes
thoroughly.
Frequency/Timing Every day, prior to the start the processing.
Responsible party
None
Procedure Put the pine apple is to be process into the
machine for peeling, cutting and crushing
processing
Frequency/Timing Always when processing at once.

Item/Description
Object/Area: Pulp Location: processing area
None
Procedure  Wash the container which is used to
weigh the pulp using normal water,
 Then wash with chlorinated hot water
thoroughly.
Frequency/Timing Every day, prior to weigh.
None
Procedure Measure the pulp weight using scale.
Frequency/Timing Whenever weighing.
Item/Description
Object/Area: E110 Location: Receiving area
None
Procedure Check the compliance of supplier’s
specification list with company’s
specification
Responsible party
Procedure
Frequency/Timing

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