HACCP Training — Foggies & Quiche — The Pie House at Cinderhill Farm

Foggies — Section 1 of 4

Products & Scope

What Foggies are and what this HACCP covers

What is a Foggy?

Foggies are premium baked pastry products with a savoury filling, manufactured at The Pie House at Cinderhill Farm. They come in Meat and Non-Meat varieties. The name reflects the local Forest of Dean heritage.

Products Covered

Beef Foggy, Lamb Foggy (Lamb Tagine filling)
Cheese & Onion Foggy, Ham & Cheddar Foggy
Roast Vegetable Foggy
Also: Fogglets (approx. 80g, frozen & RTB)
Standard size: 165g–200g by product filling

HACCP Scope — Two Product Types

Chilled RTE Foggies — Baked, packaged in plastic tamper-evident film pouches. Shelf life: 12 days (P+)
Frozen Unbaked Foggies — Packaged in cardboard boxes. Shelf life: 6 months (P+)

Pastry Types Used

Puff pastry — Vegan and Cheese & Onion Foggies
Shortcrust pastry — Beef, Lamb and Ham Foggies
Pastry arrives pre-cut to size from the pastry supplier; each sheet is weighed individually for consistency

Key Allergens in Range

Allergens vary by product. Common across the range: Gluten (wheat), Egg. Some products also contain: Milk/Dairy, Celery, Mustard, Sesame. The Lamb Tagine Foggy contains Gluten and Egg. Pastry uses Lard (except Vegan), Wheat Flour, Egg and Nigella Seeds.

Foggies — Section 2 of 4

Manufacturing Process

From receipt of raw materials to despatch

Receipt & Storage

Frozen RM: received via temperature-controlled vehicle, transit ≤24h, stored below -18°C, may remain up to 3 months
Chilled RM: stored below 8°C immediately, FIFO, up to 3 months
Ambient/Dry: FIFO dry storage, all from approved suppliers
Production room temp: 10–12°C

Filling Preparation

Vegetables washed and diced using Dirk (dicer)
Onions fried at 200°C; meat and veg added and cooked to 75°C for 2 minutes minimum
Root veg boiled before adding to mixture (Cheese & Onion, Ham Foggies)
Roast Veg Foggy: veg roasted at 180°C for approx. 25 mins then cooked to 75°C for 2 mins
Cooked filling blast chilled in small tubs to <3°C
Filling labelled with batch code and use-by (7 days from cook date), stored in filling chiller

Forming & Baking

Egg glaze prepared in designated area (electric mixer) to prevent cross-contamination
Pastry discs glazed with egg wash on bottom edge for sealing
85g of filling applied to top section of pastry disc
Pastry folded, formed and sealed
Upper side, back and sides glazed; edges crimped; toppings applied (2 wide × 5 long per tray)
Frozen unbaked: blast chilled to -18°C or below for packaged sale
Chilled RTE: baked to core temp of no less than 82°C

Cooling, Packaging & Storage

Foggies chilled down to <3°C but no lower than 0.1°C — no more than 90 minutes
RTE: food-safe bag, sealed, labelled with use-by and product label
Unbaked/frozen: cardboard box, sealed, labelled with use-by and batch reference
Finished product chilled storage: below 8°C
Finished product frozen storage: below -18°C
Total processing time from Decanting to Finished Product Chilled Storage: no more than 1.5 hours

Foggies — Section 3 of 4

Significant Risks

What the HACCP team identified as the key hazards

Most Significant Risk

Introduction, multiplication and survival of pathogenic bacteria/spores and toxin production due to inadequate temperature fluctuations throughout the manufacturing process — especially temperature-controlled storage, rapid chilling and baking steps.

All Significant Food Safety Risks

Introduction and multiplication of pathogens from chiller/freezer temperature fluctuations
Survival of pathogens during baking due to inadequate time/temperature parameters
Introduction and multiplication of pathogens from raw, unpasteurised egg (frozen unbaked only)
Cross-contamination of allergens during raw material storage, production and finished product storage
Undeclared allergens on product labels due to process cross-contamination
Chemical contamination from adulteration and substitution of raw materials (ground meat)
Physical contamination from wood (wooden pallets)
Physical contamination from extraneous matter in raw materials (bones, eggshells, hair)

Main Areas of Concern

Maintaining the cold chain throughout manufacturing
Purchase of raw materials and packaging from reputable suppliers
Segregation and prevention of allergen cross-contamination
Strict control of freezing and finished product storage temperatures (frozen unbaked)
Strict control of baking and product core temperatures (chilled RTE)
Strict control of chilling and finished product storage temperatures (chilled RTE)

Foggies — Section 4 of 4

The 5 CCPs

Critical Control Points for Foggies

CCP 1

Blast Freezing — Unbaked Frozen Products Only Target: +3°C → -18°C within 90 minutes. Critical limit: +3°C → -18°C taking MORE than 120 minutes. Reject if cooling to critical limit takes 4 hours or longer. Consider disposal if cooling exceeds 2 hours.

CCP 2

Baking — Chilled RTE Products Only Target: core temp 75°C to 99°C. Critical limit: 75°C for 30 seconds. Foggies are cooked to at least 82°C. If not reached: return to oven at 180°C. Reject product if critical limit not reached.

CCP 3

Cooling — Chilled Baked Products Only Target: core temp 90°C → >3°C within 60 minutes. Critical limit: 90°C → >3°C taking more than 90 minutes. Ambient cool <15 min, then blast chill. Reject if fails to cool below 10°C in 2 hours, or below 5°C in 2.5 hours.

CCP 4

Chilled Finished Product Storage Target: chiller maintains <4°C. Critical limit: no more than 5°C–7.9°C for less than 30 minutes. Twice daily temp checks + datalogger every 15 mins. Monthly calibration. Quarantine and discard all out-of-spec product.

CCP 5

Frozen Finished Product Storage Target: below -16°C (target -18°C to -25°C). Critical limit: -15°C to -17°C for less than 2 hours (freezer doors shut). Twice daily checks. Discard/destroy all out-of-spec product. Move stock to alternative freezer if required.

Quiche — Section 1 of 4

Products & Scope

The Quiche range at Cinderhill Farm

Products Covered

Posh Lorraine Quiche
Cheese & Onion Quiche
Spiced Vegetable Quiche
Sold in foil packs, approximately 135g each

HACCP Scope — Two Product Types

Chilled RTE Quiche — Baked, packaged in plastic tamper-evident film pouches. Shelf life: 7 days (P+) — shorter than Foggies!
Frozen Unbaked Quiche — Packaged in sealed food-safe plastic bags in crates. Shelf life: 6 months (P+)
Frozen unbaked products are stored ready for baking on premises and sold as RTE only

Key Allergens

All Quiches contain Eggs, Milk/Cream and Gluten (wheat pastry). Cheese & Onion Quiche and Posh Lorraine include dairy. The egg-rich filling (custard base) means raw unpasteurised egg is a specific hazard for frozen unbaked products.

Quiche — Section 2 of 4

Manufacturing Process

How Quiches are made — key differences from Foggies

Receipt & Storage

Frozen RM: stored below -18°C, transit ≤24h, may remain up to 3 months
Chilled RM: stored below 5°C immediately (note: Foggies use 8°C)
Ambient/Dry: FIFO dry storage

Filling Preparation

Veg prepped and fried or dry-roasted
Gammon Ham chopped
Eggs, dairy and seasoning added and mixed
Mixes added directly to pastry cases (no separate blast chilling of filling)
Topping applied for Cheese & Onion and Posh Lorraine Quiches

Blast Freeze / Bake

Frozen unbaked: placed into blast freezer on trolley to attain minimum -18°C
Chilled RTE baking: oven on trolley, cooked to minimum 75°C for 2 minutes — temperature and time both recorded

Cooling, Packing & Storage

Ambient cool <15 minutes, then blast chill on trolley to minimum 4°C — temp and time recorded
RTE packing: products moved to clean surface by clean staff in allergen-appropriate PPE; crate temp taken and recorded on batch label
Random batch sample weights checked and recorded
Goods placed in bags with card base, sealed and labelled; completed crate temperature recorded on batch label
Packed into master cases, labelled, stored in chilled temperature-controlled storage
Chilled finished product storage: below 5°C
Frozen finished product storage: below -18°C
Total processing time from Decanting to Finished Product Frozen Storage: no more than 15 minutes

Quiche — Section 3 of 4

Significant Risks

Same risk categories as Foggies, same highest risk

Quiche-Specific Risk Factors

Quiche has an egg-and-dairy custard filling. This makes it particularly sensitive to temperature control — the raw egg filling in frozen unbaked Quiche carries a higher inherent microbiological risk than most other products. Raw egg is a primary source of Salmonella.

The Most Significant Risk

Identical to Foggies: introduction, multiplication and survival of pathogenic bacteria/spores and toxin production due to inadequate temperature fluctuations — especially temperature-controlled storage, rapid chilling and baking steps.

Allergen Cross-Contamination Risk

Quiche contains multiple high-risk allergens: eggs, milk/dairy, gluten. Because egg is both a major allergen AND a raw food safety hazard (Salmonella), allergen management and microbiological controls overlap at the glaze/filling preparation steps. Allergen-appropriate PPE is specifically required during packing.

Quiche — Section 4 of 4

The 5 CCPs

Same structure as Foggies — note the differences

The 5 CCPs for Quiche are structurally identical to Foggies. Key differences are noted in violet.

CCP 1

Blast Freezing — Unbaked Frozen Products Only Identical to Foggies: +3°C → -18°C within 90 minutes. Critical limit: >120 minutes. Reject at 4 hours.

CCP 2

Baking — Chilled RTE Products Only Critical limit: 75°C for 30 seconds. Quiche is baked to 75°C for 2 minutes (time as well as temperature recorded). Return to oven at 180°C if not reached.

CCP 3

Cooling — Chilled Baked Products Only Identical to Foggies: 90°C → >3°C within 60 min (target), >90 min (critical). Ambient cool <15 min, then blast chill to minimum 4°C.

CCP 4

Chilled Finished Product Storage Target: chiller <4°C. Critical limit: 5°C–7.9°C for less than 30 minutes. Twice daily + datalogger every 15 mins. Finished product chilled storage target: below 5°C.

CCP 5

Frozen Finished Product Storage Identical to Foggies: target below -16°C (-18°C to -25°C). Critical limit: -15°C to -17°C for <2 hours with freezer doors shut. Twice daily checks.

Comparison — Section 1 of 2

Foggies vs Quiche

Key differences to know for the quiz

Side-by-Side: Key Numbers

Factor	Foggies	Quiche
RTE shelf life	12 days	7 days
Frozen shelf life	6 months	6 months
Baking core temp (RTE)	≥82°C	≥75°C for 2 min
Chilled RM storage	<8°C	<5°C
Chilled fin. product storage	<8°C	<5°C
Processing time limit	1.5 hours	15 minutes
Cooling target	<3°C (≥0.1°C)	≥4°C
Cooling max time	90 minutes	60 min target, 90 min critical
Weight	165–200g	~135g
Frozen packaging	Cardboard box	Sealed plastic bags in crates
Filling temp (prep)	75°C for 2 min	No separate cook — raw egg custard
Production room temp	10–12°C	Not specified separately

Comparison — Section 2 of 2

Shared CCP Limits

What is the same across both products

Critical Limits Shared by Both Products

75°C / 30s

CCP2 critical limit — baking (both products)

+3°C → -18°C

CCP1 target: blast freeze within 90 min

90°C → 3°C

CCP3 target: cool within 60 min

<4°C

CCP4 target: chilled storage unit

-15°C to -17°C

CCP5 critical limit: max 2h with doors shut

-18°C to -25°C

CCP5 target: frozen finished product storage

5°C–7.9°C <30min

CCP4 critical limit: chilled storage

180°C

Oven return temp if CCP2 not reached

<3 months

Max frozen RM storage (both products)

Every 15 min

CCP4 datalogger frequency (both)

The #1 Exam Trap: What's Different

Foggies bake to 82°C — but the CCP2 critical limit is still 75°C/30s for both
Quiche bake recorded as 75°C for 2 minutes (time AND temperature)
Foggies RTE: 12 days vs Quiche RTE: 7 days
Foggies processing limit: 1.5 hours vs Quiche: 15 minutes — very different!
Foggies chilled storage: below 8°C vs Quiche: below 5°C
Quiche uses allergen-appropriate PPE specifically during packing

Foggies &
Quiche HACCP

Products & Scope

Manufacturing Process

Significant Risks

The 5 CCPs

Products & Scope

Manufacturing Process

Significant Risks

The 5 CCPs

Foggies vs Quiche

Shared CCP Limits

🏆 Leaderboard

Foggies &Quiche HACCP

Products & Scope

Manufacturing Process

Significant Risks

The 5 CCPs

Products & Scope

Manufacturing Process

Significant Risks

The 5 CCPs

Foggies vs Quiche

Shared CCP Limits

🏆 Leaderboard

Foggies &
Quiche HACCP