1. GENERAL MANAGER 1 2. COFFEE MILL OPERATIONS MANAGER 1 3. ESTATE MANAGERS 8 4. QUALITY CONTROL MANAGER 1 5. PRODUCTION SUPERVISOR 1

Transcription

1 SC/FSMS/H/004

2 DISTRIBUTION LIST NO OF COPIES 1. GENERAL MANAGER 1 2. COFFEE MILL OPERATIONS MANAGER 1 3. ESTATE MANAGERS 8 4. QUALITY CONTROL MANAGER 1 5. PRODUCTION SUPERVISOR 1 Page 2 of 37

3 . DISTIBUTION LIST ABBREVIATIONS INTRODUCTION/PURPOSE TERMS AND DEFINITIONS PRODUCT DESCRIPTION RAW MATERIAL CHARACTERISTICS FINAL PRODUCT CHARACERISTICS GREEN COFFEE..7 COFFEE GRADES AND SIZES OTHER GRADES..9 CHEMICAL CHARACTERISTICS INSTANT COFFEE. 10 MICROBIOLOGICAL LIMITS ROASTED GROUND COFFEE/ ROASTED COFFEE BEANS MYTOXIN PACKAGING AND LABELLING FLOW DIAGRAMS PARCHMENT COFFEE PRODUCTION GREEN COFFEE PRODUCTION FLOW CHART ROASTING & PACKAGING OF COFFEE DESCRIPTION OF PROCESS STEPS AND CONTROL MEASURES EXISTING CONTROL MEASURES OPERATIONAL PRE-REQUISITE PROGRAM (OPRP) HAZARD IDENTIFICATION AND DETERMINATION OF ACCEPTABLE LEVELS HAZARD ASSESSMENT CRITICAL LIMITS CRITICAL CONTROL POINTS PLAN VERIFICATION PLANNING TRACEABILTY PRODUCT LOT IDENTIFICATION CONTROL OF NON-CONFORMITY...37 Page 3 of 37

4 1 ABBREVIATIONS CCP CL OPRP HACCP PRP KEBS OTA NEMA MSDS PCPB GAP CRF Company FST FSMS PPE EMCA P1,2,3 PL MH ML UG FIFO UVI MC MD GM PHI SAS PH Doc No Rev No CR L.P.O Critical Control Point Critical Limit Operation Pre-requisite Program Hazard Analysis Critical Control Point Pre-requisite Program Kenya Bureau of Standards Ochratoxin A National Environmental Management Authority Material Safety Data Sheet Pesticides Control Product Board Good Agricultural Practice Coffee Research Foundation Sasini Ltd Food Safety Team Food Safety Management System Personal Protection Equipment Environment Management Control Act Parchment Coffee Grade Parchment Light Mbuni Heavy Coffee Mbuni Light Coffee Under Grade Coffee First In First Out Ultra Violet Sheet Moisture Content Managing Director General Manager Pre Harvest Interval Sasini Limited Acidity or Alkalinity Document Number Revision Number Cleaning Records Local purchase order Page 4 of 37

5 1. Introduction/Purpose This document is developed using the guidelines of ISO 22000;2005 clause 7 and 8 with respect to hazard identification, evaluation, control and monitoring. This document presents a detailed HACCP study for the Sasini products and processes and it contains: a) Food safety hazard(s) to be controlled at the CCP. b) Control measure(s). c) Critical limit(s). d) Monitoring procedure(s). e) Correction and corrective action(s) to be taken if critical limits are exceeded. f) Responsibilities and authorities. g) Record(s) of monitoring. Page 5 of 37

6 2. Terms and Definitions For the purposes of this document, the terms and definitions given in ISO 22000;2005 shall apply: 3. PRODUCT DESCRIPTION The final products involved in the process are; 1) Green beans 2) Instant coffee 3) Roasted ground coffee 3.1 Raw Material Characteristics. The raw materials in processing of final products Red ripe Cherry. Biological The red ripe cherry is raw material for green coffee production. It is sourced from Arabica coffee variety of SL28, 34, K7, and Ruiru11. The coffee cherry is made of; Exocarp Endosperm Silver skin Outer skin Mesocarp Chemical Composition includes among others, Chlorogenic acid, caffeic acid, Ferulic acid, Quibic acid, sterols, tocopherols Kahweol, polyphenols and kauranic derivatives. Page 6 of 37

7 Physical Red ripe mature berry (a) No additives or processing aids are involved. (b) Coffee berry is produced in a large plantations of Sasini limited and from out growers. Plantations includes; Kamundu, Kakindu, Ting ang a, Doondu, Gulmarg, Ruiru mills, Mweiga and Wahenya Estates a) Coffee cherry is packed in nylon bags and delivered from the field to the processing factory using trailers. b) Coffee cherry is processed within 6 hours after picking. c) Hand- sorting to remove sticks, under ripes and mouldy beans is done prior to processing on clean mats or clean concrete floors. d) Coffee cherry should be free of mouldy beans, sticks, and stone. Kept on clean surfaces on raised table or concrete floors to avoid contaminants. 3.2 Final product characteristics Green coffee The green coffee under KS 593:2011 specification is raw material for ground roasted coffee in the value addition. a) Biological, chemical and physical characteristics Physical characteristic - Shall be practicably free from extraneous and foreign matter - Shall be free of contaminants - Shall be free from foreign odor - Shall be free from live infestation by pests, rodents and derivatives - Shall be free of fungal infestation - Shall be free from adulterants - Color grayish green, brownish green or bluish green b) Moisture content - Shall not exceed 12% when tested according to ISO Page 7 of 37

8 Coffee Grades and Sizes SI No Grade General description Screen appeture KS 174 i. E Elephant-(Retained on 21) two beans joined together, it is a genetic defect. And includes very large(bold) AA Size diameter 8.3mm ii. AA Flat beans- (through screen 21 retained in 18) Size diameter 7.2mm iii. AB Flat beans-(through screen17,retained on 17) Size diameter 6.35mm iv. PB Pea berries-(through screen 17,Retain on 12 One ovule develops instead of the usual two v. C Smaller beans- (through screen 16 retained on 10) vi. TT Light density beans, from AA,AB and E grades by air extraction vii. T Smallest, consists of broken and small C(through screen 7) Size diameter 4.76mm Size diameter3.96mm Not applicable Size diameter 2.9mm Page 8 of 37

9 Other Grades SI No Grade General Description I. MH Mbuni heavy II. ML Mbuni light III. UG Ungraded IV. SB Sorted beans V. HE Hulled ears Packaging -Average net weight of each package -bean grade -coffee year -outturn number Chemical characteristics a) Heavy metal contamination SI No Contaminants Max Limits(mg/kg) i. Lead 1.0 ii. Tin 250 iii. Arsenic 0.5 Page 9 of 37

10 b) Pesticide residues - Only pesticides approved by relevant government body (PCPB) and CRF shall be used. - Levels of pesticides shall NOT exceed recommended levels by Codex Alimentarius commission for coffee Instant coffee The raw material for preparation of instant coffee is spray dried Robusta coffee. The material must meet Kenya standard specification for instant coffee KS 175:2011. a) Biological, chemical and physical characteristics Physical characteristics - Shall free from extraneous and foreign matter - Shall be free from foreign odor - Shall be free from fungal infestation - Shall be free from adulterants - Shall be free from contaminants - The coffee shall not contain chicory - Shall have characteristic of coffee flavor Page 10 of 37

11 Chemical SI Parameter Requirements Test method i. Moisture, % by mass, max. 4 KS 1039 ii. Total ash (on dry matter basis),by mass, max 1.5 KS 1039 iii. Acid insoluble ash,% mass, max 1.0 KS1039 iv. Caffeine content(on dry basis),% by mass, min 2.8 KS ISO 4052 v. Solubility in water Dissolves readily in 30 s with moderate stirring KS 1039 vi. Solubility in cold water at 16 C ± 2 C Soluble with moderate stirring in 3min KS1039 For granulated coffee the maximum moisture content will be 5% by mass Microbiological limits The coffee shall comply with the microbiological limits tested through KS 220 method. Characteristic Limits Test Method Coliforms/10g Salmonella/30g S.aureus/10g Yeast and moulds/g Not detectable Not detectable Not detectable Less than 100cells KS 220 Page 11 of 37

12 (a) Packaging instant coffee shall be packaged in food grade containers that guarantee quality and safety of the product throughout the shelf life. (b) Labeling- shall comply with KS 40 the following information shall be legibly and indelibly marked on the package:- -name of the product as instant/soluble coffee -brand/trade name -name, location, contact details and physical address -country of origin -date of manufacture -expiry date -storage instruction -net weight in metric units -batch/lot number Roasted Ground Coffee/Roasted Coffee Beans The roasted ground /beans coffee characteristic shall be guided by KS 1052:2011 Standard Physical Characteristics - Shall be free from any extraneous and foreign matter - shall be free from foreign odour - shall be free from infestation by pests and their derivatives. - shall be free from fungal infestation -Shall be free from adulterants -shall be free from contaminants Biological Characteristics Microbiological limits Roasted ground coffee and roasted coffee beans shall comply with the microbiological limits indicated below. Page 12 of 37

13 Characteristic Limits Test Method Coliforms/10g Salmonella/30g Not detected Not detected KS 220 S.aureus/10g Not detected Yeasts and moulds/g Less than 100cells Mycotoxin Roasted ground coffee and roasted coffee beans shall comply with the mycotoxin limits of maximum of 5 ppb. SI No. Parameter Maximum limit(ppb) Test method 1 Ochratoxin A 5 ISO part 1/ Packaging and labelling Packaging -The coffee shall be packaged in food grade containers that ensure the quality and safety of the product throughout the shelf life. -The weight of container shall be ascertained with calibrated scales Labelling The following information shall be included - Name of the product - Brand name - Name, location and physical address of the manufacturer - Country of origin Page 13 of 37

14 - Date of manufacture - Expiry date - Storage instruction - Net weight - Batch/lot number Page 14 of 37

15 4. FLOW DIAGRAMS 4.1 PARCHMENT COFFEE PRODUCTION GOOD FIELD AGRICULRAL PRACTICES Washed cherry Mbuni coffee Water from rivers, dams PULPING DRY PROCESS. Water to recycling pulp to decomposing Pre-grading channel Cherry reception/sorting Fermentation tanks Rubbish to waste Skin dry Washing Lights to re- pass pulpier Sun drying Water to waste Grading channel heavies and lights separately Water to waste Skin drying- remove all free/ excess water Sun and /or mechanical drying STORAGE Page 15 of 37

16 4.2 GREEN COFFEE PRODUCTION FLOW CHART PARCHMENT MILLING Rubbish/stones etc to waste Pre cleaning/destoning Rubbish/stones etc to waste Parchment shells Milling/hulling Husk Dust to waste-shells/ears to bagging off Grading by bean size (screening) Dust to waste shells/ears to bagging off Grading by bean density (gravity table) Remove rejects and foreign matter Manual sorting Remove rejects/and foreign matter Quality evaluation and classification GREEN COFFEE Bagging off shipment in bags Page 16 of 37

17 4.3 ROASTING & PACKAGING OF COFFEE RECEPTION OF GRADED GREEN COFFEE BEANS Green coffee from Mill INSPECTION/ANALYSIS Assessment mouldy beans and foreign matter Removal of damaged diseased beans, foreign matter SORTING ROASTING TEMP TIME QUAN TITY COOLING Time Temp KGS minutes 115 to 200 ROASTING GRINDING FINE MEDIUM COURSE FINE, MEDIUM OR COURSE ROASTED COFFEE PACKAGING TINS SATCHETS STORAGE POUCHES PACKING Pouches Sachets/Tins Temporary storage At room temperature On rows and bays On Wooden pallets Distribution Covered clean van Page 17 of 37

18 5. Description of Process Steps and Control Measures 5.2 Existing Control Measures a) GAP (Good Agricultural Practices) Chemicals residuals-phi (Pre harvest intervals) is maintained to ensure that chemicals on trees are completely dissipated before picking can be done. Tree hygiene to remove mouldy and diseased berries. b) Ground collection Cherry fallen on the ground contains moulds which can introduce afflatoxin collection from the ground shall be prohibited or ground covers are laid during picking. c) Sorting After cherry is picked sorting shall be done to eliminate contaminants. d) Clean vessels (Harvesting vessels). Harvesting vessels, bags etc and trailers shall be kept clean before picking commences to ensure no contaminants are introduced to the coffee. e) Pulping Pulping machine can damage the coffee bean and introduce moulds during the drying process. Proper setting shall be done to ensure no damage occurs on the beans. Machines moving parts shall be oiled and greased routinely to ensure no metal fillings are introduced into the parchment. The type of the grease used to oil the machine should be food grade, which does not increase hazard in the chain. f) Fermentation The monitoring of fermentation process shall be followed to ensure No moulds formation takes place between the periods before complete drying takes place. Page 18 of 37

19 g) Drying Drying on the table to reduce moisture content from 65% to 11% shall be made such that the coffee does not acquire moulds due to prolonged wetting. Monitoring of the moisture levels shall be conducted frequently. Minimum of 14 days between the times the coffee was placed on the tables should not be exceeded. In the event that the weather does not allow for sun drying taking place, mechanical driers or UVI tents shall be used. Any coffee that gets into contacts with soil during this process shall be discarded. h) Storage Mould formation during storage should be eliminated by ensuring that coffee is kept 30cm from the wall on raised wooden pallets. Page 19 of 37

20 6.0 OPERATIONAL PREREQUISITE PROGRAMS (OPRPs). PROCESS STEP HAZARD CONTROL MEASURES MONITORING PROGRAM CORRECTION AND CORRECTIVE ACTION VERIFICATION AUTHORITY RESPONSIBILITY RECORDS OF MONITORING 1 Picking and reception of coffee cherries Ochratoxin A Inspection of incoming raw materials. Factory Supervisor to check the sorting Sorting and discarding mouldy beans and extraneous matter. External Test Analysis from KEBs Estate Manager Supervisors pulping record book Isolate and handle as per the procedure for handling potentially unsafe products 2 Pulping Stones Check pulper discs Ensure there is adequate water in reservoir Ensures the disc are set properly to avoid nipping of beans that can lead to development of moulds Check sieves for intactness before and after operations Presence of water in the Aagard pregrader Use the standard gauge device to set the gap Isolate and handle as per the procedure for handling potentially unsafe products Check the presence of stones in the wet parchment on tables Annnual maintenance of the disc assembly Factory machine operator Estate Manager Annual maintenance records Pulper, Service records book during the picking season 3 Drying Ochratoxin A Dry to required moisture content between 10% and 11% m.c. Moisture analysis done on every batch after every 5 days Factory supervisor to redry if moisture is high, increase drying time, seek authority to use mechanical driers Use calibrated moisture meters Factory Supervisor Moisture test records 4 Milling stones regulate vibration, air flow and slope of the deck Check for stones in the product by sampling the clean coffee after every run Increase air flow by adjusting the lever, change the slope of the deck and increase the vibration Manufacturer s manual on trouble shooting. Mill Operator Records, for inspection of final product Maintenance records Page 20 of 37

21 7.0 HAZARD IDENTIFICATION AND DETERMINATION OF ACCEPTABLE LEVELS PROCESS STEP HAZARD ACCEPTABLE LEVELS JUSTIFICATION STATUTORY& REGULATORY REQUIREMENT PRACTICE AND PRODUCTS 1. Agronomy Chemical residuals of fungicides and pesticides. Heavy metals, lead, tin, arsenic and other residuals shall be within acceptable limits Fungicides and pesticides are used for pest and disease control may persist if GAP is not observed. Acceptable levels as per Codex commission on coffee KS 593: Processing Mouldy beans may contain Ochratoxin A Max limit <5 ppb ISO PART 1/2 Moulds contain Ochratoxin A that may cause Liver cirrhosis KS 1052:2011, Max limit <5ppb of Ochratoxin A 3. Pulping E-coli, salmonella River water contains = 2400 CFU of E coli E coli is a disease causing bacteria that can result to ill health and death No E. coli, salmonella, yeast or moulds shall be found in the final product. KS Drying Moulds may contain Ochratoxin A ISO PART 1/2 Maximum limit <5 ppb Growth due to moist conditions, poor handling,resulting from damage on parchment Moisture content shall not exceed 12% KS Storage Moulds may contain Ochratoxin A Other contaminants ISO PART 1/2 Maximum limit Growth due to moist conditions, roof leakage. floods No E. coli, salmonella, yeast or moulds shall NOT be found in the final product. <5 ppb KS Milling Stones Moulds may contain Ochratoxin A Salmonella,yeast and E-coli Within acceptable limits None in the final product Human Handling of the product during processing Stones may cause ill health to consumers, it is also a source of contamination Growth due to moist conditions, poor handling and cross contamination during hulling Employees poor hygiene & health can contaminate the final product Green coffee shall comply with the limits provided in KS Codex stan 193 Maintain GMP as guided in KS Storage and dispatch Other contaminants, such as foreign odour, adulterants, foreign matter etc Hydrocarbons during transport Green coffee shall be free of contaminants Green coffee shall be free of extraneous contaminants Codex commission on coffee KS 593:2011 Page 21 of 37

22 8. Sorting/Inspection Salmonella and E. coli,contamination while physically handling coffee None in the final product May be introduced by poor hygiene, during hand sorting,lack of proper PPE KS Roasting Hydrocarbons through use of fossil fuel(diesel) in the roaster machine Salmonella and E. coli through handling of the coffee after roasting Roasted coffee shall be free of contaminants and adulterants & foreign odour. No Bacteria shall be found in final products May cause ill health Proper roasting temperatures shall eliminate any biological hazard Roasted coffee shall meet KS 1053:2011 requirements No coli forms or salmonella in final products when KS 220 testing is done 10. Cooling Contamination adulterants,foreign odour and other extraneous matter Roasted coffee shall be free of contaminants Contaminants could be a source of ill health Roasted coffee shall meet KS 1053:2011 requirements 11. Grinding Metal contaminants Within acceptable limits KS 1052:2011 Metal contaminants either from wear and tear of processing machine or introduction from any other source Within acceptable limits KS 1052: Packaging Salmonella and E-coli introduction during manual handling/packaging Within acceptable limits KS 1052:2011 May be introduced during manual handling and poor hygiene No bacteria should be detected in final product 13. Distribution Cross contamination during transport can lead to contamination like hydrocarbons, foreign odour, pests, adulterations or having unhygienic mode of transport Final products shall be free of all sort of contaminants Unhygienic dispatching of final products may introduce contaminants Final products shall be processed, packaged, stored and distributed under hygienic conditions in accordance with Public Health Act, cap 242,KS 1500 Standard Page 22 of 37

23 7.1 HAZARD ASSESSMENT 1. Methodology, In our production chain as described in clause 7.0 the main hazards identified are, - Pesticide residual from the field. - Microbiological contamination during pulping, milling and packaging process through physical handling. - Ochratoxin A contamination during the process of pulping, drying and storage. - Stones and extraneous contamination during hulling. - Metal contamination before and after grinding of roasted coffee. - Cross-contamination during dispatch due to unhygienic conditions. 2. Risk Assessment Risk levels are determined through the severity and likelihood of occurrence of each hazard. The severity and occurrence are weighted to give the magnitude of each risk level on human health. Severity Occurrence Risk level 1- least 1- least low 2- severe 2- likely medium 3- very severe 3-very likely high The highest risks on human health shall call for stringent measures to reduce or eliminate the hazard. The point at which the risk shall be eliminated will form the CRITICAL CONTROL POINT and the point at which risk occurrence shall be minimized shall require an OPRP. Page 23 of 37

24 PROCESS STEP HAZARD SEVERITY LEVELS 1-least severe 2-severe 3-very severe OCCURANCES 1-least likely 2-likely 3-very likely RISK LEVELS CONTROL MEASURES 1. Agronomy Presence of Chemical residuals of fungicides and pesticides persistent after spray, Very Severe Accumulation of chemical residual levels may cause adverse health conditions overtime Very likely Residual levels shall be within acceptable limits. High (9) PRP (GAP) use approved chemicals observe PHI, and application rates. CCP 1-No process step is capable of reducing or elimination the hazard hence considered CCP. 2. Processing/sorting lapse in sorting may lead to presence of mouldy beans which may contain Ochratoxin A Very Severe May cause severe health problems. No control measure exists to eliminate if present Least Likely verification results of mycotoxin presence are within acceptable limits Medium(6) PRP- raw materials receipt procedure, OPRP handling of potentially unsafe Products 3. Pulping E-coli from raw pulping water Very Severe Product is not consumed in its raw form Likely Medium (6) Proper roasting at recommended roasting temperatures shall eliminate all bacteria 4. Drying Growth of moulds due to poor handling or adverse weather conditions Very Severe Ochratoxin A may cause severe health problems. Very Likely With low drying the prolonged wet condition may encourage mould growth. High (9) OPRP temperature time regimes CCP- 2,for Ochratoxin A OPRP Emergency preparedness program 5. Storage Growth of moulds due to high humidity or water contamination may lead to growth of moulds hence produce Ochratoxin A Very Severe Ochratoxin A may cause death Likely Storage facility built according to requirement to allow proper ventilation. Medium (6) PRP storage Facility maintenance to prevent leakage, or water entry FIFO for stocks control. Other contaminants Page 24 of 37

25 PROCESS STEP HAZARD SEVERITY LEVELS 1-least severe 2-severe 3-very severe OCCURANCES 1-least likely 2-likely 3-very likely RISK LEVELS CONTROL MEASURES 6. Milling Contamination by Stones during the drying process. Salmonella and E- coli, from physical handling Severe May cause further contamination of product Likely Destoner setting may cause some product to get contaminated Human activity though physical handling Medium (6) PRP increase of vibration and air flow, OPRP -inspection and maintenance.oprp cleaning of sieves and air ducts will reduce passable metal and stones parts. Inspection and maintenance of screens PRP Good maintenance practices 9 scheduled maintenance PRP Good manufacturing practices use of portable water for cleaning and PRP Good Hygiene practices for personnel 7. Storage and dispatch Growth of moulds due to poor temperature regimes or water invasion may lead to growth of moulds hence produce Ochratoxin A Very Severe Ochratoxin A may cause death Likely Storage facility built according to requirement to allow proper ventilation, Medium (6) PRP storage Facility maintenance to prevent leakage, or water entry FIFO for stocks control. 8. Inspection /sorting Sorting may introduce Salmonella and E- coli due physical handling Very Severe Likely PRP personnel Hygiene is observed. At this stage the water activity is very low not conducive for further microbial growth Medium (6) Personnel hygiene to be maintained and provision of proper PPE. Provision of antibacterial soap for hand washing. 9. Roasting Roasting machine uses diesel which may lead to Hydrocarbons contamination Least Severe May not lead to adverse heath effect on consumers Likely Low (1) Proper maintenance and cleaning GMP 10. Cooling Cross contamination by extraneous matter Least Severe Hydrocarbons may cause ill health. Least Likely Hydrocarbon contamination could result to long term health problems. Low (1) GMP, hygiene and machine maintenance. Page 25 of 37

26 PROCESS STEP HAZARD SEVERITY LEVELS 1-least severe 2-severe 3-very severe OCCURANCES 1-least likely 2-likely 3-very likely RISK LEVELS CONTROL MEASURES 11. Grinding Metal fillings Very Severe Metal contamination at this point is likely and can cause adverse health problem to consumers Very Likely Machine parts are subject to wear and tear during grinding this is a constant operation the likelihood is high. High (9) Good manufacturing practices, PRP installation of magnets OPRP magnet inspection and cleaning CCP-3 beyond this point metals contamination cannot be controlled 12. Packaging Through physical handling and packing, Salmonella and E-coli likelihood of introduction is very high. Severe Salmonella is disease causing and may lead to adverse health effects Likely Packaging is hermetical and no contact with personnel. Medium (4) PRP-Sickness reporting. Proper packaging PRP personnel hygiene 13. Distribution Cross contamination by extraneous matter Least Severe Hydrocarbons may cause ill health. Least Likely Hydrocarbon contamination could result to long term health problems. Low (1) GMP, hygiene transporting vessels. Page 26 of 37

27 7.2 CRITICAL LIMITS Rationale for choosing Critical limits. a) Chemical Residual. Pesticides and fungicides are used in the field and residual chemicals contamination could find their way into the final products. The MRL (maximum residual levels) of the chemical shall be determined by referring to MSDS or other regulatory bodies, and by allowing at least the absolute pre- harvest interval (PHI) recommended for each chemical used. b) Moisture level Coffee shall be dried from a moisture level of 65% to 11%. This shall be to reduce the level of mould formation that leads to development of Ochratoxin A; the mould causes liver cirrhosis with continued use and may lead cancer and death. Monitoring shall be done using visual and feeling method and verified through use of moisture meters. c) Roasting and Grinding Metals in the grinding of the roasted beans may end up in the final products. Removal of these metals shall require the use of a magnet before roasting and grinding. A strong magnet shall be placed in the hopper before grinding and roasting. Two samples from sachets of bamba coffee from a 12x250gm carton shall be assessed for presence of metal fillings in 50 Kgs. 100gm from every 50kgs of roasted coffee beans shall be assessed for presence of metal fillings. Page 27 of 37

28 After assessment, if the sample shall have metal fillings the coffee shall be reprocessed by passing it through the magnet. Verification analysis shall be carried out twice a year for presence of metal through an external Laboratory. Monitoring the presence of metals using a strong magnet shall determine the effectiveness of the control measure. All metals corrected by the magnet shall be kept in a bag for weighing and recording and for future reference for a period of six months. Roasting Roasting temperatures shall be monitored in order to eliminate any bacteria present in the coffee. Ground Coffee (AA, AB, or PB) Temperature Time Medium roast 100 C- 12O C 20 Mins Medium Dark 100 C- 120 C 25 Mins Kahawa bamba 100 C -110 C 10mins Medium Dark Medium C 15 mins Page 28 of 37

29 7.3 CRITICAL CONTROL POINTS PLAN FOOD SAFETY HAZARD (CCP) CONTROL MEASURES CRITICAL LIMITS MONITORING PROCEDURES CORRECTION AND CORRECTIVE ACTION RESPONSIBILITIES AND AUTHORITIES MONITORING RECORDS 1. Chemical Use of approved Maximum Residuals and recommended chemicals. Observation of the PHI residual levels as per the international requirement guide and National regulatory body Observe the preharvest interval. Amount of chemical recommended rates, spray intervals. Isolate take samples for verification for maximum residual levels of chemical. Estate Manager Picking and spray records (KEPHIS) 2. Ochratoxin A(moulds) No ground collection Proper drying of coffee (GMP) Below 11% m.c. Visual inspection and hand feeling, verification using Moisture testing meters Re-dry or recondition to 11% MC. Factory supervisors Moisture content records. Daily moisture testing after the 10 th day until dry Segregate, sort and discard Mouldy. to 11% mc 3. Metal fillings (production Unit) Use magnet to remove all the metals after grinding the roasted coffee before packaging. Zero Sample the packed coffee and test for metal fillings using a magnet. Every batch of 50kgs Re-pass the coffee through the magnet. Production supervisor metal filling monitoring sheet Page 29 of 37

30 7.4 VERIFICATION PLANNING Purpose To confirm that PRP(s) OPR(s) and elements within HACCP plan input hazards analysis is continually updated, and are within identified acceptable level of other procedures required by the organization are implemented effectively. Page 30 of 37

31 7.4.1 Verification Planning DATE PRP, OPRP ASPECT METHOD OF VERIFICATION FREQUENCY RESPONSIBILITY CORRECTIVE ACTION G.A.P Chemical residues, Chemical residues testing from external analysis results Seasonally Estate managers and Quality control Manager. Recall and discard. Drying Ochratoxin A External testing maximum limits KS 220 Twice a year Quality Manager Discard Metals metals External analysis Twice a year Quality Manager Recall and reprocess Food Storage Storage humidity and temperature for conditions of mould growth Use of thermometer and hygrometer Daily Warehouse supervisor Destroy affected lot. Premises and utility Microbiological, cross contamination, foreign matter Personnel medical tests Hygiene inspections 6 monthly Before production and at random Estate manager and Maintenance supervisor Sort and segregate and quarantine personnel. Premise inspection Distribution and transport Vehicle condition for transport 1. Proper maintenance of vessel, Before every dispatch Estate manager /operations supervisors Sort, discard and reprocess. 2.Cleaning and proper hygiene before loading and for delivery vehicles Equipment Missing parts, broken parts grease loose parts equipment hygiene Final magnet inspection Complaints Bi annually Routine Machine operator Proper maintenance. Page 31 of 37

32 Waste handling Salmonella, E.coli, foreign matter, chemical hazard - Effluent water use- open lagoons - Pulps as organic manure. Husks-use as organic manure. Routine Section managers Water treatment Water supply Salmonella, heavy metals, suspended particles Packaging materials dispose as appropriate. Water testing and purification Routine Section manager Analyze and act as per recommendation. Personal hygiene Salmonella, E.coli, foreign matters and chemical hazards Medical exam. Report, Issuance records - Personnel inspection - Proper hygiene Routine Spot/random checks Section supervisors As per public health act cap 242 and occupational health and safety act Education and training Mycotoxins, salmonella, E- Coli - Routine personal hygiene checks, - Proper pest and vermin s control Periodic as necessary Estate manager As per regulations -Training attendance. - Certificates of competence Withdraw procedure Contaminated products. Batch sampling or act as per customer complaints. annually Quality Assurance Manager Recall and reprocess or discard. Traceability Forward and backward Document sampling annually Process owners Introduce relevant documents and steps. Page 32 of 37

33 7.5 TRACEABILITY The traceability process in our production system shall be guided by the following; (a) All incoming goods (raw materials) shall have. Delivery notes and Goods return notes. (GRN). For purchased items the delivery notes shall be accompanied by invoices. Before purchase an LPO shall be raised. All the purchased items shall be recorded in a purchase register. (b) Raw materials coming from various units shall have the following; Delivery notes indicating; - Number of bags - Registration of the vessels - Type - Time of delivery - Destination - Level of compliance for parchment coffee moisture contents of 11% - Name of the dispatching personnel (b) Outgoing finished products shall have the following documents for traceability purposes (i)dispatch book/ Delivery Note - GRN number - Indicating destination - Batch number - Frippery date - KEBS sticker Page 33 of 37

34 - Vehicle delivery - Destination - Customers LPO - Loading sheet number (ii) Traceability records - Wet processing - Picking books - Delivery Note books - Field supervisor books - Factory Dispatch book (iii) Dry processing - Weigh bridge ticket - Parchment storage - Milling statement - Sample test records - Delivery notes - Outgoing statement - Delivery notes (iv) Value Addition - Delivery Note Page 34 of 37

35 - Processing records - Dispatch records - Invoices - Loading sheets - LPO registers - Sales invoices Page 35 of 37

36 7.6 PRODUCT LOT IDENTIFICATION Purpose To enable identification of product lots and their relations to batches of raw materials, processing and delivery records. Product Lot Identification Date Raw materials batches Supplier Processing method Product lot Product lot sample Delivery No. Customers Recommendation Cherry Farm/field Wet method As per number outturn no. Parchment Grower s Dry method coffee Green Coffee mill Dry method coffee 7.7 CONTROL OF NON-CONFORMITY Purpose To ensure that when critical limits of CCP(s) are exceeded or there is a loss of control of OPRP(s), the products affected are identified and controlled with regard to their use and release. Control of Non-conformity As CP/OPRP Critical limit Affected end product Assessment of end product Control Handling recommended Corrections recommended Review Field operations Maximum residue levels,(kephi S), International recommendati ons Green and Roasted ground coffee As per standards on chemical residues Use recommended chemicals ( GAP) Observe PHI Good agriculture practices Sort. Isolate or discard the affected lot As necessary Primary processing (WET) Moisture content of between 10-11% Parchment, Green coffees M.C tests using moisture meter on a lot sample. Adequate drying, testing of moisture levels G. A. P s Re drying, Reconditioning to attain acceptable m.c, use mechanical driers As necessary Page 36 of 37

37 Stones Rate of vibration/ oscillation, Volume of parchment being cleaned. Air flow control Green coffee Free from stones Proper use of pre-cleaner and de-stoner. Proper pre cleaning and servicing of the destoner Check the flow rate of coffee entering the pre cleaner. Re-pass the coffee through the de-stoner. As necessary Metal Zero. Ground coffee and instant coffee Free from metal fillings Proper use of magnet GMP Re call for reprocessing to re-correct exceeded limits. Routine Page 37 of 37