Physical Hazard HACCP Plan

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Date: November 10, 2060
Prepared by: [YOUR NAME]

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I. Hazard Identification and Analysis

This section involves identifying potential physical hazards in the production process. Physical hazards are foreign objects that accidentally enter the product, such as metal fragments, glass shards, or plastic bits.

A. List of Potential Physical Hazards

• Metal fragments

• Glass shards

• Plastic pieces

• Wood splinters

B. Analysis of Physical Hazards

Hazard	Source	Potential Impact
Metal fragments	Equipment damage	Injury, product contamination
Glass shards	Broken containers	Injury, product recall
Plastic pieces	Packaging materials	Product contamination
Wood splinters	Pallets, crates	Injury, contamination

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II. Critical Control Points (CCPs)

A Identifying CCPs

1. Receiving raw materials: Potential contamination from suppliers.

2. Production and processing: Possible hazards from machinery or the environment.

3. Packaging: Contamination risks from packaging materials.

4. Final inspection: The last opportunity to detect and address any hazards before shipment.

B Control Measures at CCPs

CCP	Control Measure
Receiving raw materials	Inspection of incoming materials, supplier certifications
Production and processing	Routine equipment maintenance, cleanliness checks, use of protective barriers
Packaging	Installation of metal detectors and X-ray machines to detect foreign objects
Final inspection	Thorough visual inspection, and use of advanced detection systems like magnet traps or sieves

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III. Monitoring Procedures

Monitoring ensures that CCPs are functioning as intended and helps detect any deviation from the established limits.

3.1 Monitoring Methods

• Routine visual inspections

• Use of metal detectors and other screening equipment

• Regular maintenance checks by trained personnel

3.2 Frequency of Monitoring

Each CCP is monitored at different frequencies depending on the potential risk involved. For example, metal detectors should be checked daily, whereas visual inspections might occur per production batch.

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IV. Corrective Actions

These are steps taken when a hazard is detected at a CCP. The aim is to eliminate the hazard and prevent recurrence.

4.1 Steps for Corrective Action

1. Identify and isolate affected product

2. Determine the source of contamination

3. Maintain a record of corrective measures taken

4. Adjust process to prevent future incidents

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V. Verification Procedures

Regular verification ensures the HACCP plan is effectively managing the potential physical hazards.

5.1 Verification Techniques

• Internal audits

• Third-party inspections

• Review of CCP monitoring records

5.2 Frequency of Verification

Verification needs to be carried out no less than once every three months, or whenever there is a noteworthy alteration in the process or a modification in the equipment used.

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VI. Record Keeping

6.1 Types of Documents

• Monitoring logs for each CCP

• Corrective action reports

• Verification records

• Employee training records

6.2 Storage and Access

Records must be stored in a manner that ensures their security, whether in a digital format or as a physical hard copy. Additionally, these records should only be accessible to individuals who have been granted the necessary authorization to review them.

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