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PRIMARY PRODUCTION

HACCP HACCP STUDY

TITLE: HACCP STUDY 1.0 Scope: The aim of the HACCP study is to identify and control all hazards associated with the primary production of peas from field selection to delivery of fresh, raw uncleaned podded peas to a processing factory. Hazards to be considered have been separated into the following groups: Microbiological safety hazards Physical safety hazards Chemical safety hazards 1.1 Microbiological Safety Hazards: Raw peas (by their nature: agricultural crop) could be contaminated with enteric or other soil related pathogens. Peas are removed from the pod in the vining process in the field therefore they are subjected to environmental pathogen contamination from soil, vegetation and contact with agricultural equipment (viners, hi-lift trailers, pea lorries). No steps within the agricultural process are designed to reduce microbial load of the peas delivered to the process factory, microbiological reduction is considered during the cleaning / blanching stages of the pea processing HACCP. There is no microbioligical specification / testing program for peas at the raw material stage. 1.2 Physical Safety Hazards (Foreign Material): Non-vegetable foreign material (e.g. glass, metal, cardboard, plastic, oils, vertebrate animals etc.) 1.3 Chemical Safety Hazards Chemicals or lubricants which in direct contact with the product may be hazardous to health, either by immediate consumption or as the result of cumulative effect. Examples include: Lubricants / Oil / Diesel / Pesticide residues / Heavy metals 1.3.1 Allergens An important chemical hazard is that of allergenic materials, the company is aware of the increased level of allergenic intolerance incidents and as such these hazards have been considered as an integral part of the HACCP. The hazards associated with allergenic reactions are as per The Food Labelling (Amendment) (England) (No.2) Regulations 2004, schedule AA1 (amended) are detailed below: -Cereals containing gluten, wheat, rye, barley, oats, spelt, kamut and their hybridized strains -Crustaceans -Eggs

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PRIMARY PRODUCTION

HACCP HACCP STUDY

-Fish -Peanuts -Soya beans -Milk -The following nuts: Almond (Amygdalus communis L.), Hazelnut (Corylus avellana), Walnut (Juglans regia), Cashew (Anacardium occidentale), Pecan -Celery -Mustard -Sesame Seeds -Sulphur dioxide and sulphites at concentrations of more than 10 mg/kg or 10mg/litre expressed as SO2 -Lupins -Molluscs

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PRIMARY PRODUCTION

HACCP HACCP STUDY

2 Study Team / Review Team:

NAME AREA OF EXPERTISE HACCP TRAINING

NINA DRURY QUALITY & SYSTEMS RISK ASSESSMENT PROTOCOLS

BSc FOOD SCIENCE CIEH INTERMEDIATE CERTIFICATE IN HAZARD ANAYSIS RSPH LEVEL 3 AWARD IN HACCP

MATTHEW HAYWARD PRIMARY PRODUCTION/ AGRICULTURAL OPERATIONS

CASCADE TRAINING

3 Product Description Product PEAS (vining , processed) Red Tractor Assurance: Fresh produce scheme Category 2 Product Description Fresh immature peas of suitable wrinkled varieties of the plant pisum sativun with organoleptic characteristics of fresh peas. Packaging Bulk product delivered on dedicated pea lorries. Storage Conditions N/A Harvested and transported directly to the processing factory in a timely manner, 150-minute product quality claims are applicable to this product. Product Life N/A Intended Use Raw material only, not intended to be consumed in raw stage, subjected to various washing, grading, blanching and freezing into bulk prior to pack into consumer packs in which the end product is intended to be cooked prior to consumption. Target Groups All Exclusions None

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PRIMARY PRODUCTION

HACCP HACCP STUDY

4 Basic Process Flow 5. Pre-requisite programs

AREA CONTROL MEASURES

SUPPLIER APPROVAL

All growers within Swaythorpe Growers are Farm Assured certified Red Tractor Assurance: Fresh produce scheme Category 2 Approved pesticide lists Field cropping history Pesticide usage records All provided prior to crop release for harvest Pesticide / HM screening as per MRL sampling policy

TRACEBILITY & PRODUCT RECALL

Full traceability program in place from field to freezer including all crop treatments including seed lot number and seed treatment. Annual product recall test 24 / 7 emergency contact

FIELD GMP Fully maintained and hygiened harvest machinery, including seed drills, harvesters, high lift trailers and pea lorries. Data sheets available for all lubricants / oils used in the field / on field machinery. Field nut policy in place.

TRAINING Field personnel full training records to include Crop / harvest hygiene Glass policy Oil / diesel policy Malicious contamination policy

STEP 1 FIELD

SELECTION / ACCEPTANCE

STEP 2 CROP DRILLING

STEP 3 CROP GROWTH

STEP 4 HARVEST

STEP 5 TRANSPORT TO FACTORY

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PRIMARY PRODUCTION

HACCP HACCP STUDY

6. Risk assessment scoring matrix HAZARD SEVERITY The potential of hazard to cause harm will vary in severity dependent of the hazard itself.

Verbal Numeric Description

Catastrophic 5 Likely to result in death Major damage to grower reputation. Permanent removal from Swaythorpe Growers Ltd

Critical 4

Potential for severe injury, major illness. Major damage to grower reputation. Suspension of grower Potential removal from Swaythorpe Growers Ltd

Moderate 3 Potential for moderate injury, lost time illness. Significant damage to grower reputation. Potential suspension from Swaythorpe Growers Ltd

Minor 2 Potential for minor injury

Negligible 1 No significant risk of injury, illness or effect on reputation.

LIKELIHOOD OF OCCURRENCE The likelihood of a hazard occurring should be calculated taking into consideration the specific controls in place relating to the hazard & historical knowledge / data relating to the hazard.

Verbal Numeric Description

Frequent 5 Hazard will occur

Probable 4 Hazard will be experienced

Occasional 3 Some manifestations of the hazard are likely

Remote 2 Manifestations of the hazard are possible but unlikely

Improbable 1 Manifestations of the hazard are unlikely

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PRIMARY PRODUCTION

HACCP HACCP STUDY

HAZARD RISK MATRIX – RISK RATING

FREQ

UEN

CY

5 5 10 15 20 25

4 4 8 12 16 20

3 3 6 9 12 15

2 2 4 6 8 10

1 1 2 3 4 5

1 2 3 4 5 SEVERITY

Unacceptable risk zone Activity must be prohibited until further controls are introduced to bring the hazard to an acceptable level. Acceptable risk zone Risk is adequately controlled, and no further control is required. Risk as low as reasonably practicable Controls have been put in place to reduce the risk to as low as reasonably practicable.

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PRIMARY PRODUCTION

HACCP HACCP STUDY

7. Critical control point determination

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP

1. FIELD SELECTION

/ACCEPTANCE

C Contaminated land toxic waste / heavy metals / allergenic

materials.

4 1 4 Approved suppliers with Assured Produce certification.

Previous cropping history made available to Swaythorpe Growers as

part of approval process.

Y N Y Y No It is a pre-requisite that full crop history

& soil analysis is provided and assessed by Swaythorpe

Growers.

P Potential for contamination of non-crop material

4 2 8 Field visual inspection carried out with consideration of public

walkways / road ways / laybys in close proximity to the field

Y N Y Y No Field walking Raw material assessment at process plant

Raw material for further processing.

M Pathogenic bacteria from human / animal waste application to

land

4 1 4 Approved suppliers with Assured Produce certification.

Previous cropping history made available to Swaythorpe Growers as

part of approval process.

Y N Y Y No It is a pre-requisite that full crop history

& soil analysis is provided and assessed by Swaythorpe

Growers.

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP

2. CROP DRILLING

C Use of contaminated seed / seed with

unapproved treatments.

Use of contaminated

drill cross contamination with

cereal seed

5 1 5 Seed purchased directed from approved seed breeders.

UK approved seed treatments. Full traceability on seed use /

treatment.

Full hygiene of drill post drilling of cereal crops.

Y N Y Y No Full traceability all applications /

treatments checked prior to harvest

approval.

3. CROP GROWTH

C Use of non-approved pesticides on growing crop

Use of incorrect application rates

5 1 5 Swaythorpe Growers approved pesticide list issued annually to all

growers.

Recommendations made by BASIS trained agronomists whom have access to Swaythorpe Growers

approved pesticide list.

Application of pesticides by NRoSO equipment/operators (National

Register of Spray Operators)

Y N Y Y No All pesticide applications are

subject to audit by BASIS certified

personnel prior to field release for

harvest.

Crops with unapproved

pesticides will not be harvested.

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP 4.

HARVEST C Unapproved

pesticides

Incorrect application rate

Harvest Interval not

elapsed

Allergenic material Crop Incidental continuation via lubricants Incidental contamination from harvest team

5 1 5 Swaythorpe Growers approved pesticide list issued annually to all

growers.

Recommendations made by BASIS trained agronomists

Application of pesticides by NRoSO

equipment/operators (nation register of spray operators)

All pesticide applications are subject to audit by BASIS certified personnel prior

to field release for harvest

Crops with unapproved pesticides will not be harvested.

Harvest approval copied to processing factory unapproved loads will not be

processed. Oil / lubricant contamination policy in

place Nut policy in place.

Y Y - N YES All pesticide applications are

subject to audit by BASIS certified

personnel prior to field release for

harvest.

Crops with unapproved PPP’s

will not be harvested.

Harvest approval required by the factory prior to

processing peas.

Annual MRL analysis carried out.

Historical data available

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP

4. HARVEST

(continued)

P Contamination with non-crop-based

material

3 2 6 Regular field walking / additional inspection carried out where public

walkways / road ways / laybys in close proximity to the field

Pre-requisite controls:

Regular maintenance / daily hygiene inspection of harvesting equipment Field personnel are trained in good harvest practice / contamination / malicious contamination policies.

Y N N NO Raw material assessment at

processing facility

Product cleaning stages and further assessment post

cleaning

Feedback from factory on potential field contamination

Pre-requisite control

C Hydraulic Oil / diesel contamination

4 2 8 Pre-requisite control All harvest personnel signed off on oil / diesel contamination policies including safe refueling away from

crop and clean up / reporting procedures.

Y N N NO Pre-requisite controls in place.

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP

4. HARVEST

(continued)

M Contamination from harvest machinery /

crop residue

1 3 3 Pre-requisite control All field personnel sign off on harvest hygiene procedures.

Y N N NO Pre-requisite controls in place.

Raw material

undergo washing and microbial reduction via

blanching during processing stages.

5. TRANSPORT

M Contamination from lorry body / crop

residue

1 3 3 Pre-requisite control All field personnel sign off on harvest hygiene procedures.

All vehicles undergo pre-use

inspection including previous use, pre-use hygiene.

Y N N NO Pre-requisite controls in place.

Raw material

undergo washing and microbial reduction via

blanching during processing stages.

Lorry bodies rinsed out as part of the tipping process at

the factory

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PRIMARY PRODUCTION HACCP HACCP STUDY

STEP HAZARD

RISK CONTROL MEASURES

DECISION TREE QUESTIONS

JUSTIFICATION

TYPE DETAIL S L RR 1 2 3 4 CCP

5. TRANSPORT (continued)

P

Non crop contamination

during transportation

3 1 3 Pre-requisite control All loads are fully covered with load covers until arrival at the processing factory

Y N N NO Pre-requisite control

Raw material assessment at

processing facility

Product cleaning stages and further assessment post

cleaning

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PRIMARY PRODUCTION HACCP HACCP STUDY

8. PRODUCT SAFETY SCHEDULE

CCP STEP

HAZARD CONTROL CRITICAL LIMIT

MONITORING PROCEDURE

CORRECTIVE ACTION

RESPONSIBILITY RECORDS

1

Harvest

Pesticide Residues in

harvested crop

Harvest interval obeyed

Approval to

harvest

Approval to process

Nil in product Pesticide application records

Routine pesticide

analysis

Destroy harvested

crop

Swaythorpe Growers

YG

Technical manager

Pesticide application

records

Residue analysis results.

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PRIMARY PRODUCTION HACCP

HACCP STUDY

9.QUALITY PLAN

TIMESCALE STEP RECORDS

1.

FIELD SELECTION / ACCEPTANCE

HISTORICAL FIELD DATA

SOIL ANALYSIS APPLICATION RECORDS

2.

CROP DRILLING

SEED PURCHASE RECORDS

SEED TRACEABILITY CROP PLAN

CONTINUITY PLANNING

3.

CROP GROWTH

CROP INSPECTION CHEMICAL RECOMMENDATION

CHEMICAL APPLICATION ADVANCE SAMPLING

FIELD WALKING

4.

HARVEST CCP 1

FIELD WALKING HARVEST APPROVAL HYGIENE CHECKLIST

LOAD TICKET 150 MINUTE START TIME

TRANSPORT TO FACTORY

COMPLETED TICKET

16

WEEKS

HI

< 2 HRS