Flow Charts and Hazard Analysis
We make many, many different meat products at our plant. Our current HACCP Flow Charts and Hazard Analysis documents group products into categories that cover the same hazards but not necessarily the same cook times, cool times, etc. For SQF, is it required to have a seperate Flow Chart and Hazard Analysis for each individual product?
You need to have a separate plan for product TYPES
cook / cool times are managed by individual procedures and batch records
So for example, let's say you make sausages, we can even assume that they are the exact same recipe (so same exact hazards) but one is breakfast size and one is dinner size----------clearly they will not cook and chill at the same speed (or even at the same temperature) BUT for your HACCP plan needs, they will be in the same HACCP plan as they are the same product TYPE
Now, if you cut and package, say chicken and pork (on different days) you'd need to have a separate HACCP plan for those because even though they are both raw meat, the inherent hazards are NOT the same (as per a proper HA)
Or you do raw and cooked chicken cutlets those would be 2 separate plans OR you could have 2 parts to 1 plan where part 2 picks up where part 1 left off
We make many, many different meat products at our plant. Our current HACCP Flow Charts and Hazard Analysis documents group products into categories that cover the same hazards but not necessarily the same cook times, cool times, etc. For SQF, is it required to have a seperate Flow Chart and Hazard Analysis for each individual product?
Short answer, no. For example we have hundreds of SKUs produced under one Flow Chart and Hazard Analysis for our "Heat Treated, Shelf Stable" HACCP plan.
The differences between the individual products can be defined elsewhere in your product specifications.
We are a packaging manufacturer and we a thousand or so items as well but one HACCP plan as we only make paperboard packaging. We do have a flow diagram for each operation - Receiving, storage each production operation (sheeting, die cut, printing, finishing, storage, and shipping and identify the potential hazards for each flow diagram.
Thanks for the replies. Already have in place then. Those were the answers I needed to hear lol.
Only thing I can add in is to ensure you have some documented, clear-cut way of delineating how cook time and cool times are chosen for the various products, as well as how those are relayed to the personnel running the lines. I see no issue with grouping like items together in your HACCP (so long as an independent check of them reveals the HA is indeed matching). But say you're talking about 1 cooking line and want to cook Item X at 20 min/400F with a 15 min quick chill, but then Item Y runs at 25 min/350F with a 10 min quick chill... You need a defense as to why changing the time/temp/cooling is permissible for these products, and a procedure of how to communicate the changes for each product, with instruction as to how the different criteria are recorded and verified on the line.