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Unipex Dairy Products Co. Ltd.;

P.O. Box 5646 , Sharjah , U!.

Document : HACCP Manual Revision No. : 05

Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0

$.0" Good Manufacturing Practice:

GMP (Good Manufacturing Practice) is basic requirement of any food factory. It is

a guideline for food establishments governing personnel requirements, hygiene,

sanitation and food handling practices.

Personnel:

At nipe! "e have given basic food hyg iene training to al l our #ey "o r#men

"ho handle the food product or "ho "or#s in such a place that his practices

may affect the product safety.

Personnel H%giene

All personnel that come into contact "ith food are maintaining a high standard

of personal hygiene.

$and "ash stat ions are instal led at al l entrances to process areas and their

use is enforced each time personnel enter and leave the production area. %hey

are regular ly maintained and c leaned to #eep them in good "or# ing order.

&lectronic eye operated ('on ontact) t aps are used to prevent hand contact.

$and d is in fectant d ispensers are s i ted c lose to the product ion l ine to a l lo"

addit ional rapid hand disinfection and good quali ty disposable paper t issues

are made available at all the time.

%he use of d isposable p last ic or rubber g loves g ive some protect ion "here

product is handled but the gloves are changed "henever they become damaged

so i led. I t is made c lear to a l l "or#men that the "ear ing of g loves does not

mean that personnel may free ly handle contaminated i tems of p lant , or that

regular hand "ashing is not necessary.

Product ion personnel are g iven c lean "hite protective c loth ing*s "hich are

changed regularly. +isposable plastic aprons are also #ept at entrance to

have more protection .

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Practice of covering $air and beards is in place to avoid any entry into product

by fall ing loose hair from "or#men.

All employe es are trained to ensure that there is no eat ing, drin#ing or smo#ing

in production area and no "atches or e"ellery should be "orn.

Glass"are*s are not carried to production area.

-ashroom faci l i t ies can act as sources of contamination and so it is al"ays

#ept clean. Posters are f i t ted to remind personnel to "ash their hands before

reentering process areas.

&ngineers and maintenance personnel are trained to "or# in production area.

Maintenance personnel a re adher ing to the hyg iene rules app li cable to

production personnel.

I f the person is fee l ing s ic# "hi le on duty or a t home, he "i l l report to sh i f t

e!ecutive and shift e!ecutive "il l ta#e further required action to send him to

hospi ta l , a f ter recover ing he "i l l come up "ith doctor *s reports . /eports are

maintained.

MANAG&M&NT:

&ffective management of both personnel and processes is absolutely essential

to the prevent ion o f p roduct con tamination . %he overal l phi losophy o f our

management is one of preventive 0uality Assurance rather than retrospective

0uality ontrol.

Management has made available sufficient budget and resource to fully implement staff training

and education programmes. %he continual updating and improvement of hygiene standards isour management goal.

GMP in 'tores:

i. (o ra) *ateria+ or pacin% *ateria+ +ies in the stores )ithout "ein% checed

"y the -ua+ity Contro+ Dept.

ii. he stocs +yin% in the stores are rotated.

iii. ++ the *ateria+ is ept on p+at'or*s a"out 4 to 5 inches a"o$e %round and

a)ay 'ro* side )a++s.

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i$. Sea+ed containers )hich are opened 'or -ua+ity Contro+ inspection, as 'ar as

possi"+e are i**ediate+y issued to production 'or use and not ept open 'or

+on% ti*e.

$. he stocs are ordered as per re0uire*ent. -uantity ordered depends on she+'

+i'e, *ini*u* econo*ica+ 0uantity 'or transport and consu*ption, so that

stocs do not %et spoi+ed or da*a%ed.

$i. 1a) *ateria+s are recei$ed as per speci'ications.

$ii. (o insecticides or pesticides are stored in the area )here 'ood *ateria+ is

stored.$iii. Pest contro+ is done *onth+y.

ix. ++ the ite*s are proper+y +a"e+ed at a++ ti*es in the stores.

x. La"e+in% 2 sta*pin% o' inner "oxes 'a*i+y pacs, outer cartons etc. 'or

production use are proper+y done )ith respect to production 2 expiry dates,

code nu*"er and $ariety na*e.

xi. !ach and e$ery ite* is separate+y stored and there is no *ixin% up o' the

ite*s in the stores.

xii. 1ejected %oods are returned "y the stores as 'ar as possi"+e i**ediate+y and i'

they are ept in the stores 'or a short period, they are +a"e+ed as 31!!C!D

and 'o++o) up is done 'or returnin% the sa*e to the supp+iers under proper

docu*entation.

GMP in Mix Room:

i. ++ the dry in%redients especia++y sta"i+iers and e*u+si'iers )hich are added

in s*a++ 0uantities are )ei%hed accurate+y and *ixed thorou%h+y to a$oid

+u*pin% o' the %u*s.

ii. 1a) *ateria+s to "e used are tasted or%ano+eptica++y and ensured it is 'it 'or

production "e'ore use.

iii. he *ix is pasteuried at 7/8C 'or /5 seconds in 9S.

Care is taen that the pasteuried *ix is not he+d at this te*perature in any

case *ore than / hours, other)ise the $iscosity o' the *ix increases and it is

di''icu+t 'or the pu*p to pu++ the *ix and pass throu%h p+ate chi++er.

i$. he *ix is ho*o%enied at &7::/::: and 4::5:: psi at & st < /nd sta%e

respecti$e+y, )hi+e *ix is at 65 to =:C. >or $iscous *ixes pressure ran%es

'ro* &5:: to /::: psi.

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$. he on +ine 'i+ters in "et)een are opened and )ashed as o'ten as possi"+e to

re*o$e the so+id partic+es o' [email protected] or %u*s or any other so+ids deposited on

the 'i+ter.

$i. his *ix is coo+ed to 4 to =C throu%h the p+ate chi++er "e'ore "ein%

trans'erred to a%ein% $ats. So*e $iscous *ixes di''icu+t to pass at =8C, in this

case te*p )i++ "e "e+o) &58C and consu*e *ix )ithin /: hrs.

$ii. @ix is pre'era"+y a%ed 'or *in / hours "e'ore it is taen 'or 'reein%.

$iii. he $ats are e*pty and thorou%h+y c+eaned "e'ore passin% 'resh *ix into it.

ix. @ixes )hich are a%ed 'or *ore than 47 hours, are retested 'or acidity, and i're0uired can "e reprocessed "e'ore use.

x. he te*perature o' *ix in a%ein% $at is *onitored throu%h the insta++ed Ca+

Contro+ e*p. recordin% syste*. #n case o' 'ai+ure te*p. shou+d "e *anua++y

recorded in the *ix re%ister.

xi. Batch nu*"er and type o' *ix and date can "e put on the $at i' re0uired to

a$oid %ross *isuse o' *ix.

GMP in Production:

i. @ixes co+ored and '+a$ored, ready 'or 'reein% are tasted 'or '+a$or and co+oror%ano+eptica++y.

ii. he 'roen product co*in% 'ro* 'reeer is checed 'or te*perature o' 'reein% A

4 to 6C, "ody and texture.

iii. he 0uantity o' secondary in%redients %oin% into the product is checed 'or its

con'or*ity )ith standard 'or*u+ations.

i$. Pacs o' #ce Crea* are coded 'or the "atch nu*"er and production code nu*"er,

so that it is easy to trace 2 +ocate the product in case o' product reca++.

$. !xcess unused pacin% *ateria+ o' the day +yin% in the production ha++ is returned

to the stores under proper docu*entation or ept at desi%nated p+ace.

$i. he +e't o$er excess opened cartons o' ra) *ateria+ 2 pacin% *ateria+ areproper+y co$ered to a$oid insect in'estation and ept in order unti+ they are

consu*ed.

$ii. La"e+s o' '+a$our "ott+es are retained unti+ the product is consu*ed and the "ott+es

are ti%ht+y capped as the essence are $o+ati+e and the stren%th o' the '+a$or *ay

decrease and a+so conta*ination *ay tae p+ace. >#>O is o"ser$ed strict+y.

$iii. Durin% inter$a+s o' production, containers o' secondary in%redients "ein% added

to are co$ered )ith +ids to a$oid 'orei%n *ateria+ conta*inatin% the product.

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ix. he ca+ciu* ch+oride A"rine so+ution so+ution is checed 'or speci'ic %ra$ity and

p9. Speci'ic %ra$ity shou+d "e &./7. 9i%her the concentration *ore is the 'reein%

capacity.

x. Durin% the chan%e o$er o' product in case o' "ars and candies, the *ou+ds are

thorou%h+y c+eaned and no *ix o' pre$ious production is +e't o$er in the *ou+ds.

+so nuts "o+ts and spies are ti%ht enou%h not to 'a++ into the product.

xi. ++ *eta+ detectors are )orin% and $eri'ied 'or its 'unctionin%.

xii. (o %+ass apparatus +ie *easurin% cy+inders or jars are used in productions.xiii. O$errun or )ei%ht per piece o' the product is checed on +ine as per standard.

xi$. Under'i++in% or o$er'i++in% o' products shou+d not do.

x$. Secondary in%redients are tasted "e'ore use. Care is taen )hi+e addin% to 'ruit

'eeder to a$oid any conta*ination )hi+e hand+in%.

x$i. 1e)or i' any is added to *ix "+ender in appropriate *ix "atches "e'ore

pasteuriation in *ix roo* and detai+s recorded on *ix process contro+

sheet.

GMP in Despatch and Cold Room Section:

i. e*peratures o' the co+d 1oo* are noted re%u+ar+y in the +o% "oo 2 *onitor thete*p. recordin% syste* is )orin%.

ii. (o #ce Crea* is ept direct+y on the '+oor.

iii. #t is ensured #ce Crea* does not re*ain in the air+oc roo* 'or unnecessari+y +on%

ti*e "e'ore it is "ein% trans'erred to the Co+d1oo*.

i$. Care is taen )hi+e trans'errin% the pacs, and are not hand+ed rou%h+y )hich

*ay resu+t in de'or*in% o' the pacs.

$. #ce Crea* is issued to *aret on >#>O A>irst in >irst Out "asis )ith the he+p o'

production 2 expiry and dates and production code.

$i. he $ehic+es in )hich the ice crea* is transported to dea+ers 2 distri"utors are

thorou%h+y c+eaned.

$ii. #ce crea* is transported in re'ri%erated ehic+es at &78C or "e+o) and te*p. is

recorded.

$iii. 1eturns or *e+ta%es recei$ed, checed and disposed o''.

ix. #ce crea*s returned 'ro* the *aret in 'air+y %ood condition are not *ixed up

)ith the other stoc in Co+d 1oo*, "ut ept iso+ated and are issued 'irst.

x. Loose #ce Crea* units are ept separate+y in one p+ace in the Co+d 1oo* and are

issued 'or 'ree sa*p+es and %uests and sta''.

xi. he Co+d 1oo* and ir +oc roo* doors are ept c+osed at ti*es.


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Shipping Guidelines:

&. !xport container #nspection is done and recorded in 'or*at pro$ided "e'ore

+oadin%. #n case o' non con'or*ance in'or* to La"oratory sta'' and tae

correcti$e action su%%ested and *aintain the record.

/. !nsure e*perature o' container is achie$ed &78 C "e'ore +oadin%.

?. !nsure Co+d Store te*perature is "e+o) &78C "e'ore re*o$in% stocs to +oad.

4. Do not store pa++ets in ir +oc *ore than &: *inutes.5. rran%e a++ pa++ets in side the co+d store in %u++y pre'era"+y.

6. >u++ tracea"i+ity is recorded )hi+e shippin% and record shou+d "e easi+y a$ai+a"+e

'or *ini*u* &/ *onths.

=. One )or*en )ho is ept 'or door openin% and c+osin% )ith co+d roo* dress

and he shou+d "e a+on% )ith o' the 'or+i't to open and c+ose the doors o' co+d

stores as )hen needed and ensure that air is +oced "et)een co+d stores and

outside. #' co+d roo* door is open then door o' air+oc shou+d "e c+osed and $ice

$ersa. his shou+d "e strict+y 'o++o)ed )ith dedication "y a++.

7. Doors o' containers )hi+e +oadin% shou+d "e c+osed i**ediate+y in "et)een the

+oadin% as needed ti++ )e *ae co$ered +oadin% "ay.

. !nsure that te*perature inside container is "e+o) &78C a'ter +oadin% and "e'ore

container is re+eased 'ro* the %ate and te*perature and other detai+s are recorded

as per 'or*at.

&:. Put t)o disposa"+e te*perature data +o%%ers in side the container "e'ore +ea$in%.


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