HACCP
Training

Food poisoning from pathogenic bacteria such as E. coli O157, Listeria monocytogenes, Salmonella, Bacillus cereus, Staphylococcus aureus, Clostridium botulinum and Enterobacteriaceae. Also includes Weil's disease from leptospirosis bacteria.

Foreign objects including wooden splinters (from pallets), pest droppings, stones, personal effects (jewellery, phones), hair, hard brittle plastic, glass, general metal objects, sharp metal, fibrous matter, sealant, flaking paint, soft plastic.

Mycotoxins, packaging contaminants, cleaning chemical residues, cooling agents (e.g. glycol), lubricants, ink (coding ink, henna), medicines, heavy metals, radioactive materials, pesticides.

The 14 key allergens. At Cinderhill Farm, relevant ones include: Milk, Gluten (Wheat/Rye/Barley/Oats), Celery, Sesame, Soya, Mustard, Nuts, Peanuts, Sulphites. Also risk from adulterated raw ingredients and cross-contamination via suppliers or facility.

• Pathogen multiplication from chiller/freezer temperature fluctuations
• Pathogen survival due to inadequate baking time/temperature
• Pathogen introduction from raw unpasteurised egg (frozen unbaked products)
• Allergen cross-contamination during storage, production and packaging
• Undeclared allergens on product labels
• Chemical contamination from adulterated/substituted raw materials
• Physical contamination from wooden pallets or raw material foreign matter

Each hazard is scored on two dimensions, each rated 1–3:

• Severity (S): 1=Low, 2=Medium, 3=High
• Likelihood (L): 1=Remote (unlikely but conceivable), 2=Possible (could occur sometime), 3=Likely

Multiply S × L to get the Risk Rating (1–9).

• 1–2 = LOW — Controlled by PRPs
• 3–5 = MEDIUM — Controlled by PRPs
• 6 = MEDIUM/HIGH — Controlled by PRPs (extra vigilance)
• 7–9 = HIGH — PRPs + CCP Monitoring required

Only HIGH-scoring hazards (7+) progress to CCP assessment. A score of 6 triggers extra vigilance but is not a CCP.

A CCP is a process step that is essential to prevent, eliminate, or reduce a food safety hazard to an acceptable level. It is always the LAST step where a particular hazard can be controlled. CCPs are determined using the Codex Decision Tree (Q1–Q5).

• Chilled deliveries rejected if above +5°C
• Frozen deliveries rejected if above -16°C
• Defrosting: never refreeze thawed products. Label with date defrosted and use-by (24h)
• Dispose of chilled ingredients that exceed +5°C for more than 4 hours
• Discard cold food kept above 8°C for more than two hours during distribution
• Post-cook rest time: ≤30 minutes before blast chilling or freezing
• All stores to be checked twice daily
• Data logger test of delivery: twice yearly

Food deliveries from contracted suppliers only. All chilled deliveries must be ≤+5°C; frozen ≤-16°C. No goods accepted if best-before/use-by exceeded, packaging damaged, showing pest signs, or without a full ingredient list. Stored within 15 minutes of delivery.

All four delivery types (ambient, chilled, frozen, packaging) require visual inspection. Chilled ≤+5°C, Frozen ≤-16°C. Reject if contaminated, out of date, or missing labels. Allergen information must be provided for all ingredients.

All food off the floor. Stock rotated FIFO. Allergens stored separately; powdered allergens in airtight containers. No loss of product description after decanting. Daily date code and pest checks.

Twice daily temperature checks: +1°C to ≤+5°C. Only food ≤+5°C placed in refrigerator. Daily stock rotation and date code checks. Dispose of anything exceeding +5°C for more than 4 hours due to malfunction.

Temperature: -18°C to -22°C. Twice daily checks. Dispose of anything defrosted (unless defrosted before use). Adjust thermostat if temperature above -18°C.

Store off floor in designated area. Open packets in lidded containers. No chemicals or cleaning agents in dry store. Daily pest checks. Dispose of any packaging contaminated by pests or chemicals.

Defrost raw food away from high-risk RTE foods. Temperature test to ensure completely thawed (+1°C to +5°C within 24 hours). Label with defrost date and 24h use-by. NEVER refreeze thawed products.

Wash all raw herbs and vegetables with potable water. Colour-coded equipment (chopping boards). Dried pulses inspected and rinsed. Cover and date prepared ingredients if not used immediately. Isolate and identify any improperly washed vegetables.

Visually inspect and pre-wash all cereal grains and pulses. Boil potatoes and pulses until tender. Roast onions until soft with slight brown colour. Check ALL ingredients (including secondary) for allergens. Blue food-safe gloves required.

Maximum 30 minutes at ambient temperature per batch. Correct bucket colours used. Visual check for foreign bodies (plastic wrapping, blue paper etc). Check all ingredients for allergens. Discard any ingredient in contact with allergenic ingredient not in recipe.

Carried out during mixing and forming. Maximum 30 minutes ambient. Blue food-safe gloves. Calibrated and cleaned weighing equipment. Supervisor checks staff compliance.

Re-working carried out as per steps 8a (ambient prep), 8b (cook prep) and 10 (weigh/cut). All the same controls apply.

Cook to the correct time/temperature per SOP for each product. Use calibrated temperature probe — check top, middle and bottom of each rack row. Record the LOWEST temperature found. Continue cooking until core temp reaches CCP limits. Allergenic products cooked separately or at oven bottom.

Post-cook rest: ≤30 minutes in high-risk area (products still >70°C during this time). Then blast chill to ≤+5°C. Use calibrated probe on last tray into chiller. If core temp not ≤+5°C, return to chiller. If limits not met or quality unacceptable — reject batch.

Post-cook rest: ≤30 minutes in high-risk area (products still >70°C). Then blast freeze to ≤-18°C. If core temp not ≤-18°C, return for further freezing. If limits not met — reject batch. Calibrated probe used throughout.

Air conditioning at 16°C. Minimise ambient exposure time. Visual checks; legible dates and batch codes. Dispose of product >+5°C after 4 hours. Correct food-safe packaging. Label checks against allergen information. Reject incorrect or illegible labels.

Same controls as Packaging (Step 15). Air conditioning at 16°C. Dispose of product >+5°C after 4 hours. Check batch codes and dates are legible.

Target: +5°C. Tolerance: +1°C to ≤+5°C. Critical limit: +5°C. Twice daily temperature checks. Only food already ≤+5°C placed in chiller. Dispose of anything exceeding +5°C for >4 hours due to malfunction.

Refrigerated vehicle below +5°C. Products in ice-pack packaging; must reach customer below +5°C within 24 hours. Data logger test twice yearly. Discard food kept above 8°C for more than 2 hours during transport.

Same as Step 15 (Packaging) but for frozen products. Dispose of product >-15°C after 4 hours. Air conditioning at 16°C. Full allergen label checks.

Temperature: -18°C to -22°C. Twice daily checks. Monthly date code and stock checks. Do not lose product description after decanting. Dispose of defrosted items and anything exceeding dates.

Refrigerated vehicle below -18°C. Products in ice-pack packaging. Data logger test twice yearly. Discard food kept above 8°C for more than 2 hours during transport. Clean vehicle or use appropriate alternative immediately if below standard.