Saran SIMPULAN DAN SARAN
Ingredients Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse health effect
high? Yes No Based on historical data and the
current situation, is the likelihood of occurrence unacceptable?
Please attach supporting data. Yes No
Is this managed through existing PP?
Yes No Is the Ingredient Process Step to
be documented as a risk in the HACCP plan?
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If YES name PP programs.
If NO managed through HACCP complete Table 2
If existing PP – NO If Managed through HACCP - Yes
Soy Lecithin Biological E.coli, Salmonella
NA NA
No – Not biologically sensitive ingredient
PP – RM Specs PP - CoA
No Chemical Heavy Metal
No No
No - Supplier information PP - Hazard Supplier
No Chemical Pesticide residue
No No
No - Supplier information PP - Hazard Supplier
No Physical None
NA NA
No - observations of extraneous material
PP - Incoming Inspection No
Coffe Powder Biological None
NA NA
No – Not biologically sensitive ingredient
PP – RM Specs No
Chemical Heavy Metal No
No No - Supplier information
PP - Hazard Supplier No
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Non Dairy Creamer
Biological E.coli, Salmonella NA
NA No – Not biologically sensitive
ingredient PP – RM Specs
PP - CoA No
Chemical None NA
NA No - Food ingredient
PP - RM Specs No
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Vanilla Flavor V123
Biological None NA
NA No – not biologically sensitive
material, artificial flavour in Propylene Glycol
PP – RM Specs No
Biological None NA
NA No - Food Flavoring
PP - RM Specs No
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Cappuccino Flavor
C123 Biological None
NA NA
No – not biologically sensitive material, artificial flavour in Propylene
Glycol PP – RM Specs
No Chemical None
NA NA
No – Food flavoring PP – RM Specs
No Physical None
NA NA
No - observations of extraneous material
PP - Incoming Inspection No
Mint Flavor M123 Biological None
NA NA
No – not biologically sensitive material, artificial flavour in Propylene
Glycol PP – RM Specs
No Chemical None
NA NA
No – Food flavoring PP – RM Specs
No Physical None
NA NA
No - observations of extraneous material
PP - Incoming Inspection No
Hazelnut Flavor H123
Biological None NA
NA No – not biologically sensitive
material, artificial flavour in Propylene Glycol
PP – RM Specs No
Chemical None NA
NA No – Food flavoring
PP – RM Specs No
Ingredients Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse health effect
high? Yes No Based on historical data and the
current situation, is the likelihood of occurrence unacceptable?
Please attach supporting data. Yes No
Is this managed through existing PP?
Yes No Is the Ingredient Process Step to
be documented as a risk in the HACCP plan?
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If YES name PP programs.
If NO managed through HACCP complete Table 2
If existing PP – NO If Managed through HACCP - Yes
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Hazelnut Paste
HP123 Biological E.coli, Salmonella,
S.aureus Yes
Yes No - Supplier information
PP - Hazard Supplier No
Chemical Allergen-hazelnut Yes
Yes No - Allergen warning Allergen
labelling PP - Labelling
No Chemical Heavy Metal
No No
No - Supplier information PP - Hazard Supplier
No Chemical Aflatoxin
Yes Yes
No - Supplier information PP - Hazard Supplier
No Physical None
NA NA
No - observations of extraneous material
PP - Incoming Inspection No
Strawberry Flavor S123
Biological None NA
NA No – not biologically sensitive
material, artificial flavour in Propylene Glycol
PP – RM Specs No
Chemical None NA
NA No – Food flavoring
PP – RM Specs No
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Color Red 40
Biological None NA
NA No - Food coloring
PP - RM Specs No
Chemical None NA
NA No - Food coloring
PP - RM Specs No
Physical None NA
NA No - observations of extraneous
material PP - Incoming Inspection
No Water process
Biological None NA
NA No – Chlorine treatment
PP – Water Treatement No
Chemical Heavy Metal No
No No – Analysis
PP – Annually Water Analysis No
Physical None NA
NA No – treated water
PP – Filtration Treatment and Water Analysis
No Water forming
Biological None NA
NA No - Chlorine and UV treatment
PP – Water Treatement No
Chemical Heavy Metal No
No No – Analysis
PP – Annually Water Analysis No
Physical None NA
NA No – treated water
PP – Filtration Treatment and Water Analysis
No Crumb
Biological None NA
NA No – 3 moisture and 1 month shelf
life crumb PP - Standard of Crumb
No Chemical None
NA NA
No – Identification of Crumb PP - Labelling Plastic Procedure
No Physical None
NA NA
No - observations of extraneous material
PP - Preparation Procedure No
Ingredients Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse health effect
high? Yes No Based on historical data and the
current situation, is the likelihood of occurrence unacceptable?
Please attach supporting data. Yes No
Is this managed through existing PP?
Yes No Is the Ingredient Process Step to
be documented as a risk in the HACCP plan?
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If YES name PP programs.
If NO managed through HACCP complete Table 2
If existing PP – NO If Managed through HACCP - Yes
Packaging
Plastic bag Biological None
NA NA
No – closely packed, damaged packed rejected
PP - Incoming inspection No
Chemical non food grade No
No No - Analysis from the supplier
PP - Incoming inspection on the CoA No
Physical None NA
NA No - observations of extraneous
material PP - Incoming inspection
No Tin
Biological None NA
NA No – closely packed, damaged
packed rejected, clean container PP - Incoming inspection
No Chemical lacquer
No No
No - Analysis from the supplier PP - Analysis result
No Physical None
NA NA
No - observations of extraneous material
PP - Incoming inspection No
Case Biological None
NA NA
No – clean container PP - Incoming inspection
No Chemical None
NA NA
No – outer packaging PP – PM Specs
No Physical None
NA NA
No – damaged packaging are rejected during PM inspection
PP - Incoming Inspection and Preparation procedure
No Tray duplex
Biological None NA
NA No – clean container
PP - Incoming inspection No
Chemical None NA
NA No – outer packaging
PP – PM Specs No
Physical None NA
NA No – damaged packaging are
rejected during PM inspection PP - Incoming Inspection and
Preparation procedure No
TABEL 2 Risk Assessment RM : SECTION - Codex Decision Tree for CCP Determination Ingredient
Type of Hazard Biological, Chemical Physical
Q1-Do Preventative Measure Exist for the Identified hazard
YesNo Q2-Does this step
Eliminate or Reduce the Likely Occurrence of a
Hazard to an Acceptable Level
Q3-Could Contamination with Identified Hazards Occur in
Excess of Acceptable Levels or could these increase to
unacceptable Level s Q4-Will a Subsequent Step, prior to
Consuming the food, eliminate identified hazards or reduce the
likely Occurrence to an acceptable Level?
Is this Hazard a CCP or PP? Form C
No- Yes No
PP or Modify Step YesNo
YesNo Yes
→ Q2 Yes-
Yes- → Q4
CCP Yes-
PP No-
→ Q3 No –
No- PP
CCP
Full Cream Milk Powder
Biological E.coli, Salmonella, S.aureus
Yes No
No NA
PP - CoA, Internal External Analysis Program
Whey Powder Biological E.coli, Salmonella
Yes No
No NA
PP - CoA, Internal External Analysis Program
Coccoa Powder Alkalized
Biological E.coli, Salmonella Yes
No No
NA PP - CoA, Internal External
Analysis Program
Step 6 Principle 1 : Hazard Identification Process Step
Type of Potential Hazard Biological, Chemical, Physical
Risk Assessment only fill if the ingredient step is a Potential Hazard Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion?
Yes No Is the risk of
serious, adverse health effect high?
Yes No Based on historical data and the
current situation, is the likelihood of occurrence unacceptable?
Please attach supporting data. Yes No
Is this managed through existing PP?
If YES name PP programs. If NO managed through HACCP
complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
Note : involves manual handling Incoming Material
1.a. CheckingTesting
Palm Oil Biological None
NA NA
No - Use of clean and sanitized sampling tools
PP - Incoming Material Procedure No
Chemical None NA
NA No - Use of clean and sanitized
sampling tools PP - Incoming Material Procedure
No Physical None
NA NA
No - Use of clean and sanitized sampling tools
PP - Incoming Material Procedure No
1.b. Transfering Palm Oil through
hose and pump from delivery truck
Biological None NA
NA No -Checking the transfer hose and
pipe PP - Incoming Raw Material Inspection
No Chemical None
NA NA
No -Checking the transfer hose and pipe
PP - Incoming Raw Material Inspection No
Physical None NA
NA No -Checking the transfer hose and
pipe PP - Incoming Raw Material Inspection
No 1.c. Storing Palm oil
in Storage tank Biological None
NA NA
No - Closed tank PP - Storing Procedure
No Chemical None
NA NA
No - Closed tank PP - Storing Procedure
No Physical None
NA NA
No - Closed tank PP - Storing Procedure
No 2.a.
CheckingTesting the non bulk
ingredients Biological None
NA NA
No - Use of clean and sanitized sampling tools and Reject Procedure
for Damaged Ingredients PP - Incoming Raw Material Inspection
No Chemical None
NA NA
No - Use of clean and sanitized sampling tools and Reject Procedure
for Damaged Ingredients PP - Incoming Raw Material Inspection
No Physical None
NA NA
No - Use of clean and sanitized sampling tools and Reject Procedure
for Damaged Ingredients PP - Incoming Raw Material Inspection
No 2.a. Storing non bulk
ingredients in warehouse
Biological None NA
NA No - Storage in the correct condition
PP - Storing Procedure No
Chemical Allergen Yes
Yes No - separation with the pallet
PP - Allergen Handling PP - Product Labelling
No Physical None
NA NA
No - Storage in the correct conditio PP - Storing Procedure
No
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
3.a. CheckingTesting
Packaging Materials Biological None
NA NA
No - Reject Procedure for Incoming PM
PP -Incoming PM Inspection No
Chemical None NA
NA No - Reject Procedure for Incoming
PM PP -Incoming PM Inspection
No Physical None
NA NA
No - Reject Procedure for Incoming PM
PP -Incoming PM Inspection No
3.b. Storing Packaging Materials
in warehouse Biological None
NA NA
No - Storage in the correct condition PP - Storing Procedure
No Chemical None
NA NA
No - Storage in the correct condition PP - Storing Procedure
No Physical None
NA NA
No - Storage in the correct condition PP - Storing Procedure
No 4.a. Storing water in
tank well and Chlorination
Biological None NA
NA No - Chlorine Treatment to reduce
microbial load PP - Water Treatment Program
No Chemical None
NA NA
No - residual chlorine Check PP - Water Treatment Program
No Physical None
NA NA
No - Closed system PP - Water Treatment Program
No 4.b Filtering of water
Biological None NA
NA No - Filter specification
PP - Water Treatment Program No
Chemical None NA
NA No - Filter specification
PP - Water Treatment Program No
Physical None NA
NA No - Closed tank
PP - Water Treatment Program No
4.c. Passing water through UV
Biological None NA
NA No - UV treatment to reduce
microbial load PP - Water Treatment Program
No Chemical None
NA NA
No - UV treatment, no chemical added
PP - Water Treatment Program No
Physical None NA
NA No - Closed system
PP - Water Treatment Program No
Preparation of Materials 2.a. Packing the
wheat flour in plastic bag
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - use of clean plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean plastic bag
PP - Material Preparation Procedure No
2.b. Weighing wheat flour
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
2.c. Labeling wheat flour
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
3.a. Milling the sugar
Biological E.coli Yes
Yes Yes
No Yes
Chemical Grease No
No No - Maintenance Schedule
PP - Maintenance Schedule Physical Metal
Yes Yes
No - product will pass through magnet sieve 30 mesh
PP - Process Design
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
3.b. Packing the sugar into container
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
3.c. Weighing the sugar
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
3.d. Labelling the sugar
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
4.a. Packing ingredients in plastic
bag Biological E.coli
Yes Yes
Yes No
Yes
Chemical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
4.b. Weighing the ingredients
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
Physical None NA
NA No - use of clean scoop
PP - Material Preparation Procedure No
4.c. Labelling ingredients
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
5. Combining each ingredients based
on the formula on a pallet
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Mixing on batter mixer 1. Transfering pallet
in the batter mixing area
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
2. Pumping of water into mixing tank
Biological None NA
NA No - Closed system
PP – Water Treatment Procedure No
Chemical None NA
NA No - Closed system
PP – Water Treatment Procedure No
Physical None NA
NA No - Closed system
PP – Water Treatment Procedure No
3. Dumping of ingredients from
pallet to mixing tank Biological E.coli
Yes Yes
Yes No
Yes
Chemical None NA
NA No - GMP Hand sanitizing with
Alcohol every 1 hour PP - Hand Sanitation Procedure
No Physical None
NA NA
No – Use clean plastic PP - Material Preparation Procedure
No 4. Mixing of all
ingredients for batter Biological None
NA NA
No – Mixing Time PP – Mixing Procedure
No Chemical None
NA NA
No – no use of chemical PP – Equipment Design
No Physical Metal
Yes Yes
No - Pass through sieve 30 mesh PP - Process Design
No
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
5. Transfering mixed batter through pump
motor Biological None
NA NA
No - Closed system PP – Mixing Procedure
No Chemical None
NA NA
No - Closed system PP – Mixing Procedure
No Physical None
NA NA
No - Closed system PP – Mixing Procedure
No 6. Sieving mixed
batter through vibrating screen
Biological None NA
NA No – Use of Cleaned and Sanitized
equipment PP - Change Over and Weekend
Cleaning Procedure No
Chemical None NA
NA No - no use of chemical
PP - Equipment Design No
Physical Metal Yes
Yes Yes
No Yes
7. Collecting of mixed batter into
mobile tank Biological E.coli
Yes Yes
Yes No
Yes
Chemical None NA
NA No - no chemical use
PP - Tool Mobile Tank Design No
Physical None NA
NA No - use cleaned mobile tank
PP - Mixing Procedure No
8. Labelling of tank Biological None
NA NA
No – Closed tank PP – Production Procedure
No Chemical None
NA NA
No – Closed tank PP – Production Procedure
No Physical None
NA NA
No – Closed tank PP – Production Procedure
No 9. Transfering of
batter from mobile tank to oven area
Biological None NA
NA No – Closed tank
PP – Production Procedure No
Chemical None NA
NA No – Closed tank
PP – Production Procedure No
Physical None NA
NA No – Closed tank
PP – Production Procedure No
Mixing on the ball mill mixer
1. Transfering pallet in the ball mill area
Biological None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Chemical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
Physical None NA
NA No - closed plastic bag
PP - Material Preparation Procedure No
2. Pumping opening valve of
palm oil into Ball mill Biological None
NA NA
No - closed plastic bag PP - Material Preparation Procedure
No Chemical None
NA NA
No - closed plastic bag PP - Material Preparation Procedure
No Physical None
NA NA
No - closed plastic bag PP - Material Preparation Procedure
No 3. Dumping of
ingredients from pallet to mixing tank
Biological E.coli Yes
Yes Yes
No Yes
Chemical None NA
NA No - GMP Hand sanitizing with
Alcohol every 1 hour PP - Hand Sanitation Procedure
No Physical None
NA NA
No – Use clean plastic PP - Material Preparation Procedure
No
4. Mixing of all ingredients of cream
Biological None NA
NA No – Cleaning equipment every
change over and weekend PP - Change Over and Weekend
Cleaning Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical Metal Yes
Yes No - Pass through magnet and sieve
30 mesh PP - Process Design
No
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
5. Transfering of mixed cream
through pump motor Biological None
NA NA
No - Closed system PP - Mixing Procedure
No Chemical Allergen
Yes Yes
No – cleaning change over PP – Cleaning Change over Procedure
PP - Allergen Handling PP - Product Labelling
No Physical None
NA NA
No - Closed system PP – Mixing Procedure
No 6. Passing the
cream through magnet
Biological None NA
NA No - Closed system
PP – Mixing Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical None NA
NA No – Magnet Treatment for Physical
Handling PP – Process Design
No 7. Sieving the cream
through vibrating screen
Biological None NA
NA No – Use of Cleaned and Sanitized
equipment PP - Change Over and Weekend
Cleaning Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical Metal Yes
Yes Yes
No Yes
8. Dispensing of cream into the
transfer tank Biological None
NA NA
No - Closed transfer tank PP – Production Procedure
No Chemical Allergen
Yes Yes
No – cleaning change over PP – Cleaning Change over Procedure
PP - Allergen Handling PP - Product Labelling
No Physical None
NA NA
No – Use of Cleaned Mobile Tank PP - Change over and weekend
cleaning Procedure No
9. Transfering of transfer tank to oven
Biological None NA
NA No - Closed transfer tank
PP – Production Procedure No
Chemical None NA
NA No - Closed transfer tank
PP – Production Procedure No
Physical None NA
NA No - Closed transfer tank
PP – Production Procedure No
Flute wafer baking, Forming Cream Filling
1. Transfering of cream and base to
oven tank through flexible hose and
pump Biological None
NA NA
No – closed system PP – Production Procedure
No Chemical Allergen
Yes Yes
No – cleaning change over PP – Cleaning Change over Procedure
PP - Allergen Handling PP - Product Labelling
No Physical None
NA NA
No – Closed system PP – Production Procedure
No 2. Dispensing of
cream through nozzle
Biological None NA
NA No – closed system
PP – Production Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
Physical None NA
NA No – Closed system, cleaned nozzle
PP – Production Procedure No
3. Dispensing of batter to rotating
drum Biological None
NA NA
No – baking characteristic PP - Baking temperature Profile
No Chemical None
NA NA
No - no chemical used PP - Equipment Design
No Physical None
NA NA
No – cleaning the overcooked batter weekly
PP - Cleaning Weekend Procedure No
4. Baking Biological None
NA NA
No – Baking treatment for microbiological handling
PP – Baking Temperature and Baking Time exceed standard for killing
microbes No
Chemical None NA
NA No - no chemical used
PP - Equipment Design No
Physical None NA
NA No – Closed system, cleaning the
overcooked batter PP – Cleaning Weekend Procedure,
Oven Procedure No
5. Flute forming Biological E.coli
Yes Yes
No – Standard for changing the cloth, verification the microbiology of cloth
while in use, use distilled water PP – Changin Cloth Procedure, Swab
Test Schedule, Incoming Non RM-PM No
Chemical None NA
NA No - no chemical used
PP - Equipment Design No
Physical None NA
NA No – Standard for changing the
clothes PP – Changing Cloth Procedure
No 6. Cream filling
Biological None NA
NA No – Closed system
PP – Production Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical None NA
NA No – Closed system
PP – Production Procedure No
7. Cutting of flute wafer
Biological None NA
NA No – Cleaning and Alcohol Sanitation
on Equipment before start PP - Change over and weekend
cleaning Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical Metal Yes
Yes Yes
No Yes
8. Transfering wafer to chute
Biological None NA
NA No – GMP Alcohol Sanitation on
Equipment PP - Change over and weekend
cleaning Procedure No
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical None NA
NA No – Cleaning and Alcohol Sanitation
on Equipment before start PP - Change over and weekend
cleaning Procedure No
Process Step Type of Potential Hazard
Biological, Chemical, Physical Is consequence immediate
minutes, hours, days and
linked to specific event of ingestion? Yes No
Is the risk of serious, adverse
health effect high? Yes No
Based on historical data and the current situation, is the likelihood
of occurrence unacceptable? Please attach supporting data.
Yes No Is this managed through existing
PP? If YES name PP programs.
If NO managed through HACCP complete Table 2.
Is the Ingredient Process Step to be documented as a risk in the
HACCP plan? If existing PP – NO
If No- The Potential hazard will be controlled in
Prerequisite Program If No- The Potential
hazard will be controlled in
Prerequisite Program
If No- The Potential hazard will be controlled in Prerequisite
Program If managed through HACCP -YES
Wafer packaging storage
1. packing of wafer to bag
Biological E.coli Yes
Yes Yes
No Yes
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical None NA
NA No – Visual Inspection of the
bagtransparant tray PP – Packing Procedure
No 2. Weighing of wafer
in bag Biological E.coli
Yes Yes
Yes No
Yes
Chemical Allergen Yes
Yes No – cleaning change over
PP – Cleaning Change over Procedure PP - Allergen Handling
PP - Product Labelling No
Physical None NA
NA No – Visual Inspection of the
products on bagtray PP – Packing Procedure
No 3. Passing of
bagthrough metal detector
3. Passing of bagthrough metal detector
NA NA
No – Visual Inspection of the products on bagtray
PP – Packing Procedure No
Chemical None NA
NA No - no chemical used
PP - Equipment Design No
Physical None Yes
Yes Yes
No Yes
4. Sealing the bag Biological E.coli
Yes Yes
Yes No
Yes
Chemical None NA
NA No - no lubrication applied
PP - Equipment Design No
Physical None NA
NA No – Visual Inspection of the
products PP – Packing Procedure
No 5. Packing into tin
Biological None NA
NA No – closed foil
PP – Packing Procedure No
Chemical None NA
NA No – closed foil
PP – Packing Procedure No
Physical None NA
NA No – closed foil
PP – Packing Procedure No
7. Packing in shipping carton
Biological None NA
NA No – closed foil
PP – Packing Procedure No
Chemical None NA
NA No – closed foil
PP – Packing Procedure No
Physical None NA
NA No – closed foil
PP – Packing Procedure No
6. Coding of shipping carton
Biological None NA
NA No – closed foil
PP – Packing Procedure No
Chemical None NA
NA No - separate storage for chemical
PP - Chemical Handling Procedure No
Physical None NA
NA No – closed foil
PP – Packing Procedure No
8. Storage of FG Biological None
NA NA
No – closed carton PP – FG Storage Procedure
No Chemical None
NA NA
No – closed carton PP – FG Storage Procedure
No Physical None
NA NA
No – pest control PP – Pest Control
No 9. Loading FG to
container Biological None
NA NA
No – closed carton PP – FG Loading Procedure
No Chemical None
NA NA
No – incoming container checking PP – Incoming Container Checking
No Physical None
NA NA
No – incoming container checking PP – Incoming Container Checking
No
Step 7 Principle 2 CCP
Process Step Type of Hazard Biological,
Chemical Physical Q1-Do Preventative Measure
Exist for the Identified hazard YesNo
Q2-Does this step Eliminate or Reduce
the Likely Occurrence of a Hazard to an
Acceptable Level Q3-Could Contamination with
Identified Hazards Occur in Excess of Acceptable
Levels or could these increase to unacceptable
Level s Q4-Will a
Subsequent Step, prior to
Consuming the food, eliminate
identified hazards or reduce the likely
Occurrence to an acceptable Level?
Is this Hazard a CCP or PP?
No- PP or Modify Step Yes No
YesNo YesNo
Yes → Q2
Yes- CCP Yes-
→ Q4 Yes- PP
No- → Q3
No -PP No- CCP
Preparation of Materials
2.a. Pack the wheat flour in plastic bag
Biological E.coli Yes
No No
NA PP - Baking Process
2.b. Weighing wheat flour
Biological E.coli Yes
No No
NA PP - Baking Process
3.a. Milling the sugar Biological E.coli
No NA
NA NA
PP - Low Aw of cream, PP - GMP Hand Sanitation
3.b. Packing the sugar into container
Biological E.coli No
NA NA
NA PP - Low Aw of cream,
PP - GMP Hand Sanitation 3.c. Weighing the
sugar Biological E.coli
No NA
NA NA
PP - Low Aw of cream, PP - GMP Hand Sanitation
4.a. Pack ingredients in plastic
bag Biological E.coli
No NA
NA NA
PP - Baking Process, PP - Low Aw of cream,
PP - GMP Hand Sanitation 4.b. Weighing
ingredients Biological E.coli
No NA
NA NA
PP - Baking Process, PP - Low Aw of cream,
PP - GMP Hand Sanitation
Preparation of Batter Mix 4. Dumping
ingredients from pallet to mixing tank
Biological E.coli Yes
No No
NA PP - Baking Process
7. Sieving the mixed batter through
vibrating screen Physical Metal
Yes No
Yes Yes
PP - Metal Detector 8. Collecting the
mixed batterinto mobile tank
Biological E.coli Yes
No No
NA PP - Baking Process
Preparation of Cream 4. Dumping of
ingredients from pallet to mixing tank
Biological E.coli Yes
No No
NA PP -GMP Hand Sanitation
Process Step Type of Hazard Biological,
Chemical Physical Q1-Do Preventative Measure
Exist for the Identified hazard YesNo
Q2-Does this step Eliminate or Reduce
the Likely Occurrence of a Hazard to an
Acceptable Level Q3-Could Contamination with
Identified Hazards Occur in Excess of Acceptable
Levels or could these increase to unacceptable
Level s Q4-Will a
Subsequent Step, prior to
Consuming the food, eliminate
identified hazards or reduce the likely
Occurrence to an acceptable Level?
Is this Hazard a CCP or PP?
No- PP or Modify Step Yes No
YesNo YesNo
Yes → Q2
Yes- CCP Yes-
→ Q4 Yes- PP
No- → Q3
No -PP No- CCP
8. Sieving the cream through vibrating
screen Physical Metal
Yes No
Yes Yes
PP - Metal Detector
Flute Wafer Packing Storage
7. Cutting of flute wafer
Physical Metal Yes
No Yes
Yes PP - Metal Detector
1. Packing of wafer to bag
Biological E.coli Yes
No No
NA PP -GMP Hand Sanitation
2. Weighing of wafer in bag
Biological E.coli Yes
No No
NA PP -GMP Hand Sanitation
3. Passing of bag through metal
detector Physical Metal
Yes Yes
CCP - Metal detector 4. Sealing the bag
Biological E.coli Yes
No No
NA PP -GMP Hand Sanitation
ABSTRACT
Rosteliana Apririanty. Assessment on Implementation of the British Retail Consortium Global Standard for Food SafetyIssue 6 PT SSI. Under the direction
of HARSI DEWANTARI KUSUMANINGUM and BETTY SRI LAKSMI JENIE.
The British Retail Consortium BRC Global Standards are widely used by suppliers and global retailers, facilitating standardization of quality, safety,
operational criteria and manufacturers’ fulfillment of legal obligations. Since July 2011 the BRC Global Standard for Food Safety published the Standard issue 6
and has been implemented for certification starting at 1st January 2012. This study was conducted to assess the conformity of the BRC Standard issue 5 to
issue 6, which has been implemented since 2006 at PT SSI, a wafer stick manufacturer located in Cikupa. Re-ordering of sections and re-numbering of
clauses has been found within this standard, while 64 clauses and 223 subclauses on issue 5 become 86 clauses and 208 subclauses on issue 6. Important issue are
new clauses for outsourcing management 3.5.4 that has been induced; specifying requirements of full traceability 3.9 that must be completed in 4 hours for quick
response in a case of recall; Certification Body must be informed within 3 days in the event of product recall 3.11; and foreign body control 3.10 has been
extended which reflected the management of risk from different technologies for detecting and removal of foreign materials. There are about 20 of 158 documented
system still need to be fulfilled by PT SSI to comply with Standards Issue 6, which are supplier of services procedures and agreements 3.5; traceability 3.9
procedures must including requirements of 4 hours target of data completion; notification to Certification Body in recall procedures 3.11.4; security self
assessment 4.2.1 must be provided; more detailed calibration and verification procedures of measuring and monitoring devices and those must included
deviation tolerance 6.3, and a consistent personnel training and competencies reviews programs 7.1. Further study on the implementation of allergen
management indicated that fully identification production line including supporting tools and dedicated cleaning procedure should be provided for product
containing allergen, i.e. wafer chocolate-hazelnut. The assessment on foreign body control implementation identified improvement for specifying procedures in
case of breakage of glass 4.9.3 as required in issue 6 and sieves application for crumb milling process to prevent contamination.
RINGKASAN
ROSTELIANA APRIRIANTY. Kajian Penerapan the British Retail Consortium Global Standard for Food Safety Isu 6 PT SSI. Dibimbing oleh HARSI
DEWANTARI KUSUMANINGRUM dan BETTY SRI LAKSMI JENIE.
PT SSI adalah industri wafer stik dan kukis yang memasarkan produknya ke 40 negara di dunia dengan pasar utama adalah Amerika Serikat, Inggris,
Australia, Selandia Baru, Singapura, dan Cina. Dalam persaingan dan perdagangan internasional, jaminan penerapan dan sertifikat sistem keamanan
pangan memiliki tempat khusus dan menjadi persyaratan. Sejak 2011 ada 2 sistem yang disertifikasi yaitu the BRC Global Standard for Food Safety dan SQF 2000
level 3, dimana semua pelanggan dapat menerima sertifikat tersebut. BRC dikeluarkan pertama kali pada 1998, dibangun sebagai kerangka kerja bagi
produsen pangan memproduksi pangan yang aman dan mengelola mutu produk sesuai persyaratan pelanggan. Format dan isi didesain agar dapat dilakukannya
suatu kajian kesesuaian bangunan pabrik, sistem operasional dan prosedur perusahaan oleh pihak ketiga yang kompeten yaitu Badan Sertifikasi. BRC isu 6
diterbitkan pada Juli 2011 dan diberlakukan untuk audit sejak 1 Januari 2012. Penelitian bertujuan mengkaji standar dan implementasi the BRC Global
Standard for Food Safety isu 6 ke dalam sistem keamanan pangan di PT SSI, yang menerapkan dan tersertifikasi BRC sejak 2006. Tujuan khususnya adalah
mengidentifikasi perubahan persyaratan pada isu 6, menetapkan dokumen dalam rangka pemenuhan persyaratan isu 6 dan mengkaji serta menyusun rekomendasi
implementasi manajemen alergen dan pengendalian benda asing PT SSI.
Penelitian diawali dengan mempelajari satu per satu klausul BRC isu 5 dan isu 6 untuk mengidentifikasi perbedaan persyaratan pada kedua versi. Kajian
kesesuaian persyaratan dokumen sistem, prosedur, atau catatan dilakukan melalui desk evaluation dengan cara membandingkan persyaratan dokumen dengan
dokumen yang dimiliki PT SSI meliputi manual, prosedur, form atau checklist, standar, spesifikasi dan lainnya. Rekomendasi implementasi manajemen alergen
ditetapkan melalui kajian potensi kandungan alergen dalam produk; kajian proses mulai dari pembelian, transportasi dan penyimpanan bahan baku, penyiapan
bahan per-batch, proses dan penjadwalan produksi termasuk rework; pembersihan dan sanitasi; serta pelatihan karyawan. Rekomendasi pengendalian benda asing
ditetapkan melalui kajian sumber benda asing pada berbagai tahapan proses mulai dari penerimaan bahan sampai pengemasan produk; kajian standar maksimal
setiap benda asing; kajian prosedur dan fasilitas pengendalian; serta kajian prosedur verifikasi dan dokumentasi.
Persyaratan BRC terdiri dari 7 bagian yaitu komitmen manajemen senior bagian 1, rencana HACCP bagian 2, sistem manajemen keamanan dan mutu
pangan bagian 3, standar pabrik bagian 4, pengendalian produk bagian 5, pengendalian proses bagian 6, dan karyawan bagian 7. Perubahan jumlah
klausul yaitu dari total 223 subklausul pada isu 5 menjadi 208 subklausul pada isu 6 karena adanya pergeseran bagian, pengurangan atau penggabungan klausul-
klausul, serta beberapa persyaratan baru yang dikembangkan dari isu 5. Hubungan antara kebijakan keamanan dan mutu pangan perusahaan dengan sasaran mutu
serta kajian manajemen senior lebih diperinci dalam klausul 1.1.1-1.1.3. Persyaratan organisasi perusahaan 1.2.1 pada isu 5 terletak di bagian 3.
Prerequisite programmes 2.2 dimasukkan sebagai persyaratan baru yang menunjukkan hubungan antara prerequisite programmes dan HACCP.
Persyaratan pemasok jasa dipisahkan dari pemasok bahan baku 3.5.3. Beberapa persyaratan baru adalah terkait manajemen pengerjaan proses di luar perusahaan
3.5.4, daya telusur harus dilakukan dalam waktu 4 jam 3.9 agar memungkinkan penanganan penarikan produk yang cepat, serta Badan Sertifikasi
harus diinformasikan dalam waktu 3 hari bila terjadi penarikan produk 3.11. Kajian kemanan 4.2.1 harus rutin dilakukan termasuk penetapan akses masuk ke
area produksi dan area penyimpanan di pabrik 4.2.2. Klausul 4.3 mensyaratkan dilakukannya kajian pembagian area menjadi low-risk area, high-care area atau
high-risk area serta penerapan persyaratan bangunan pabrik 4.4, fasilitas karyawan dan aturan higiene pada tiap area 4.8. Pengendalian kontaminasi fisik
dan kimia dikembangkan dengan mensyaratkan pengendalian potensi kontaminasi dari kegiatan pemeliharaan, bahan untuk pemeliharaan baik kontak atau tidak
kontak dengan bahan baku dan produk harus food grade 4.7.5, catatan inspeksi bahaya dan investigasi tersedia bila terjadi kehilangan peralatan logam tajam
4.9.2.1, dan larangan penggunaan staples di area produk terbuka 4.9.2.2. Pemilihan teknologi untuk deteksi dan penghilangan benda asing 4.10.3-4.10.5
dilakukan berdasarkan kajian resiko. Bahaya alergen dikaji sebagai potensi bahaya pada pengembangan produk baru 5.2.3. Prosedur pengendalian alergen
5.2.4 lebih terperinci terkait penggunaan pakaian pelindung seragam; pengaturan jadwal produksi produk; pengendalian debu, limbah dan luapan bahan alergen;
dan pelabelan 5.2.6. Mass balance test terkait daya telusur identity preserved materials harus diuji minimal setiap 6 bulan 5.3.2. Terdapat pengembangan
persyaratan terkait spesifikasi produk dan proses 6.1.1. Agen penyedia tenaga kerja perusahaan adalah harus melakukan pelatihan 7.1.4 dan pemeriksaan
kesehatan karyawan 7.2.4. Audit laundri untuk pakaian high-care area dan high- risk area wajib dilakukan 7.4.4.
Dari sekitar 158 dokumen sistem, prosedur dan sistem yang disyaratkan dalam isu 6 terdapat sekitar 20 dokumen yang teridentifikasi diperlukan
perusahaan dalam rangka pemenuhan persyaratan. Dokumen tersebut terkait prosedur dan perjanjian pemasok jasa 3.5, daya telusur harus dilakukan dalam
waktu 4 jam 3.9, kajian resiko keamanan perusahaan 4.2.1, prosedur kalibrasi dan verifikasi peralatan pemeriksaan yang dilengkapi dengan batas toleransi 6.3,
dan pelaksaan pelatihan serta kajian kompetensi karyawan yang konsisten 7.1.
Alergen merupakan senyawa penyebab terjadinya alergi, yaitu gangguan kesehatanyang bervariasi mulai dari yang ringan seperti gangguan pada kulit
sampai menimbulkan anafalitik hebat yang berakibat pada kematian AFGC 2007. Tujuan utama pengaturan dalam manajemen alergen adalah agar tidak
terjadinya kontaminasi silang dari bahan alergen. Semua produk wafer menggunakan bahan baku yang berpotensi mengandung alergen berupa tepung
terigu, susu, telur, dan lesitin kedelai tetapi khusus wafer chocolate hazelnut juga menggunakan pasta hazelnut. Karena pada label semua bahan tadi telah
dicantumkan dalam komposisi sedangkan hazelnut belum, maka bahaya alergen yang harus dikendalikan adalah pada pasta hazelnut atau chocolate-hazelnut.
Bahaya alergen pada hazelnut dikategorikan sebagai bahaya kimia dalam rencana
HACCP PT SSI. Rekomendasi yang diberikan untuk perbaikan implementasi manajemen alergen adalah perlunya pemisahan dan pelabelan jelas pada semua
peralatan pendukung, agar tidak terbatas pada mesin dan peralatan utama seperti ball mill mixer dan oven, pemisahan dan pelabelan alergen pada peralatan
pembersihan, serta penggunaan test kit-ELISA untuk pengujian residu alergen pada hasil pembersihan mesinperalatan bekas produksi dengan hazelnut atau
chocolate-hazelnut.
Pengendalian benda asing di PT SSI telah dilaksanakan dengan baik melalui prerequisite programmes dan pengendalian bahaya pada rencana HACCP.
Pada tahap penerimaan barang direkomendasikan pengaturan staples pada prosedur penerimaan bahan baku dan kemasan, dilakukannya prosedur
pemeriksaan pada tambahan pemeliharaan mesin dan peralatan untuk memastikan tidak adanya potensi kontaminasi benda asing, prosedur penanganan kejadian
pecahnya kaca dimasukkan aturan pencucian seragam dan alat kebersihan yang berpotensi terkena pecahan kaca tadi, serta prosedur pembuangan pecahan kaca.
Ayakan untuk hasil gilingan crumb perlu dibuat untuk memastikan crumb bebas dari kertas, logam, dan plastik.