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Automatic Pizza PRIUS Srl

Vending HACCP Via Molini, 3


Machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

SPS
AUTOMATIC
PIZZA VENDING MACHINE

HACCP
MANUAL

© Copyright Sitos November 2008 edition rev. 04 July 2009


All rights reserved. No parts of this document can be copied or disseminated in any way without the written consent of Sitos srl

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


All rights reserved. No parts of this document can be copied or disseminated in any way without the written consent of Sitos srl
Page 1 of 33
Automatic Pizza PRIUS Srl
Vending HACCP Via Molini, 3
Machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


All rights reserved. No parts of this document can be copied or disseminated in any way without the written consent of Sitos srl
Page 2 of 33
Automatic Pizza PRIUS Srl
Vending HACCP Via Molini, 3
Machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

CONTENTS
1 Scope and field of application ............................................................... 5
1.1 General company data ..................................................................................................................... 5
1.2 Nomination of person responsible ................................................................................................. 5
SSOP 6
1.3 General information .......................................................................................................................... 6
1.4 Characteristics of activity ................................................................................................................ 6
1.5 Description of premises ................................................................................................................... 7
1.6 SOP (Standard Operative Procedure) ............................................................................................ 7
1.7 Premises............................................................................................................................................. 7
1.8 Water supply for washing the machine ......................................................................................... 7
1.9 Effluent drainage ............................................................................................................................... 7
1.10 Maintenance....................................................................................................................................... 7
1.11 Product supply and traceability ...................................................................................................... 8
1.12 Waste and process residue ............................................................................................................. 8
1.13 Rules to be followed prior to operation ......................................................................................... 8
1.14 Rules to be followed during operation........................................................................................... 8
1.15 Supply of constituent materials ...................................................................................................... 9
1.16 Storage of constituent materials..................................................................................................... 9
1.17 Swabbing............................................................................................................................................ 9
1.18 Temperatures..................................................................................................................................... 9
1.19 Prerequisite hygiene requirements ................................................................................................ 9
HYGIENIC DESIGN .................................................................................................................... 10

2 Sanification manual...............................................................................12
2.1 General cleaning and disinfection procedures .......................................................................... 12
2.2 Cleaning............................................................................................................................................ 12
2.3 Disinfection ...................................................................................................................................... 12
2.4 Personal hygiene ............................................................................................................................ 12
2.5 Recommended hand washing procedure ................................................................................... 13
2.6 Instructions for the correct cleaning of the Automatic Pizza Vending Machine ................... 13
¾ MIXER ............................................................................................................................... 13
¾ HOPPER AND PRE-FORMER ......................................................................................... 14
¾ PIZZA CONVEYOR .......................................................................................................... 15
¾ PIZZA OUTFEED .............................................................................................................. 15
¾ INTERNAL SPACES IN MACHINE .................................................................................. 16
¾ TOMATO SAUCE DISTRIBUTOR ................................................................................... 16
¾ REFRIGERATOR.............................................................................................................. 16
¾ CLEANING THE OVEN AND HOOD ............................................................................... 17
¾ WATER DISTRIBUTION PUMP ....................................................................................... 18
¾ FLOUR DISTRIBUTOR .................................................................................................... 18

3 PART 2: HACCP (Hazard Analysis Critical Control Point) ...............20


3.1 Hazard analysis and critical control points ................................................................................. 20

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machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

3.2 Preliminary steps ............................................................................................................................ 20


3.3 Principals.......................................................................................................................................... 20
3.4 Constitution of group ..................................................................................................................... 20
3.5 Description of product ................................................................................................................... 21
3.6 Identification of intended use of product .................................................................................... 21
3.7 Development of flow diagram ....................................................................................................... 22
3.8 Analysis of hazards associated to each step ............................................................................. 23
3.9 Identification of CCPs ..................................................................................................................... 24
3.10 Determination of critical limits ...................................................................................................... 24
3.11 Determination of CCP monitoring systems ................................................................................ 24
3.12 Determination of corrective actions ............................................................................................. 24
3.13 Documentation management ........................................................................................................ 24
4 Addenda .................................................................................................25
4.1 Addendum 0: monitoring form...................................................................................................... 25
4.2 Addendum 1: list of suppliers ....................................................................................................... 26
4.3 Addendum 2: nonconformity report form ................................................................................... 27
4.4 Addendum 3: plan of premises ..................................................................................................... 28
4.5 Addendum 4: results (if any) of microbiological swabbing ...................................................... 29
4.6 Addendum 5: list of personnel ...................................................................................................... 30
Addendum 6: refrigerator control ........................................................................................................... 31
Addendum 7: Techincal details of detergents and disinfectants ...................................................... 32
4.7 List of addenda. ............................................................................................................................... 33

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

1 SCOPE AND FIELD OF APPLICATION


Description and analysis of system
This manual has been drafted in accordance with CE Regulations n° 178/2002 - 852/2004 -
853/2004, regarding hygiene standards for foodstuffs, with the intention of describing the general
criteria applied for the use of the pizza vending machine.
The plan is based on the HACCP principles, a preventive control system that ensures constant
wholesomeness and hygiene characteristics in products, with the constant control of both pre-
processing and processing operations.

The manufacturer of the machine is Prius srl.


Prius srl provides this manual as a facsimile that can be used to complete an already existing
manual.
This document describes the system devised by Sitos srl to achieve and maintain the hygienic-
sanitary quality required to ensure the wholesomeness of the end products made with the “Automatic
Pizza Vending Machine”.

The specifications in this Hygienic and Sanitary Self-control Manual are applicable to the machine
components, the equipment and the pizza production process.
The manager of the machine is required to read this manual and either complete it with his or her
own data and apply it, or draw up his or her own plan, or implement the existing plan with the part
regarding the automatic pizza vending machine.

1.1 General company data


To be completed by the person managing the machine
Company name
Phone n°
Address
Manager
Business category
Health service authorisation
HACCP Manual drafting date
Contact person for distribution

1.2 Nomination of person responsible


I, the undersigned …………………………………………. proprietor of the business, nominate Mr

………………………………….......as the person responsible for the management of the machine

(supplies, cleaning, completion of HACCP forms, etc..)

Proprietor Person responsible for management of machine

___________________________ _______________________________

Place and date

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


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Automatic Pizza PRIUS Srl
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machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

SSOP

1.3 General information


The hygienic-sanitary quality of the pizzas made with the Automatic Pizza Vending Machine is the
result of a set of activities designed to guarantee hygiene standards in the machine’s components,
in the equipment, in the constituent materials, in the production environments, in the running of the
processes and in the activities of the personnel.
The combination of these activities determines a decrease in the risk of contamination of chemical,
biological, microbiological and physical origin and the observance of hygiene standards in the sold
end products.

These activities, implemented to guarantee hygienic-sanitary quality, include:

• design and construction of machine in line with Italian Law Decree 155/97 and Codex
Alimentarius requirements, and Regulation (CE) 852/04, 853/04 and subsequent amendments.
• analysis of company structures and logistics in order to identify hazards and contamination risks
with regard to constituent materials, semi-finished goods and end products
• definition and verification of hygiene standards with regard to constituent materials, semi-
finished goods and end products and with regard to contractors and transport companies
(quality plans and technical specifications)
• description of production process with the use of graphical representations (flow diagrams) to
highlight the single phases of the processes
• identification of hygiene hazards in processes and definition of critical control points
• definition of methods, frequencies and acceptability limits for checks on constituent materials,
semi-finished goods and pizzas
• definition of treatment procedures in the event of exceeding critical limits and corresponding
corrective actions to be taken
• identification, segregation and definition of responsibilities for the treatment of products not
conforming to hygienic sanitary standards
• definition, application and verification of cleaning and sanitizing plans for the machine and its
components and of equipment and environments
• drawing up of operating instructions for carrying out cleaning activities and for the application of
the instructions
• definition of machine operating and maintenance methods for customers and installers
• personnel hygiene awareness training
• implementation of cleaning systems
• collection and management of waste from production and returns
• definition of monitoring methods
• drawing up of documentation for documentary evidence of activities performed.

1.4 Characteristics of activity


The place where the Automatic Pizza Vending Machine is located must, as far as possible, allow
the activities to be organised in the following way:
• One-directional flow of meals production line: a clear separation between incoming constituent
material paths and food preparation and dispensing paths.
• Deliveries of constituent materials before the start of the processes.
• Structural separation of food preparation activities: the constituent material reception tasks and
the storage, preparation and meals dispensing tasks must be separate from each other.

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

1.5 Description of premises


The complex is structured as described in the HACCP Manual for the activity, with the specific
environments being structured as follows:
• Floors made of resistant, non-absorbent, washable and disinfectable materials.
• Washable walls made of resistant, non-absorbent, and disinfectable materials.
• Windows made of resistant, non-absorbent, washable and disinfectable materials.
• Doors with smooth surfaces, easily washable and disinfectable.

1.6 SOP (Standard Operative Procedure)


The handling of unpacked foodstuffs takes place during the filling of the machine.

The person responsible for the hygiene of the premises must check the expiry dates and
wholesomeness of the constituent materials used for refilling the machine, as described in the
subsequent chapters on pre-operative rules and traceability and, if nonconformities are found, he
or she must complete the form (Addendum 2).

He or she must also verify the cleanness of the equipment used on a daily basis for preparing the
food, as described in the section on Cleaning and Sanitizing.

1.7 Premises
The layout of the premises is shown in the enclosed plans (addendum 3), with the place of
installation of the Automatic Pizza Vending Machine highlighted.

1.8 Water supply for washing the machine


The drinkable water is taken from the public water mains.
All the water used for cleaning the Automatic Pizza Vending Machine and the premises, including
bathrooms and toilets, must be drinkable water.

1.9 Effluent drainage


The only effluent produced is that resulting from the cleaning of the machine.

1.10 Maintenance
In order to prevent environmental contamination that could contaminate the automatic pizza
vending machine, such as insects, mould or infestation, a maintenance plan for the premises must
be implemented which must include:
• taking corrective action to eliminate humidity and mould stains, loose plaster and paint and
cracks in walls and ceilings
• repairing or replacing broken or loose tiles
• checking and repairing loose fixtures
• checking periodically for the presence of insects, animals and/or rodents with the use of glue
traps for rodents and crawling insects and UV lamps for flying insects.
Corrective action to resolve any maintenance problems arising in premises where an
“Automatic Pizza Vending Machine” is located.
• In the event of problems with plaster, cracks in walls or broken tiles, the proprietor of the
business must ensure that the premises are kept in an excellent state of repair, with the help of
specialists when necessary.

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

• If rodents or infestations of animals or insects are discovered, either contact a specialist pest
control company or put down rodent bait at points where the rodents cannot possibly carry it to
the foodstuffs. The bait must be checked every day and replenished until the poison level
remains constant.
In any event, if nonconformities occur, compete the form in the addendum.

1.11 Product supply and traceability


All the constituent materials used for refilling the machine must be properly packed, labelled and
provided by authorised suppliers. In particular, every pack must bear the expiry date and lot
number in a visible position.
For Traceability purposes, the documents accompanying the goods must bear the lot number.

1.12 Waste and process residue


The waste consists of packaging and food waste.
Boxes and glass are separated for recycling.
The remaining waste is classified as solid urban waste and can be disposed of in normal rubbish
bins.

1.13 Rules to be followed prior to operation


The person responsible for the self-control must monitor the state of hygiene and cleanliness of the
environments, equipment and persons and complete the monitoring form (Addendum 0), with
reference to the following points in particular:

1. Check the Automatic Pizza Vending Machine and location premises thoroughly to ensure that
they are at the same level of cleanliness-disinfection as when they were closed.
2. Check the external areas around the premises to ensure that there are no nonconformities
(animal excrement, accumulated rubbish, etc.).

3. Remove rings, bracelets watches and other such items and wear suitable working clothes
including a hat or head cover, making sure that all your hair is tucked away inside it.

4. Before starting to refill the Automatic Pizza Vending Machine, wash your hands thoroughly in
detergent and hot running water then dry them completely with a single-use towel. Your nails
must be kept short, clean and without varnish.

5. If any nonconformities are observed, the person responsible for the self-control must take the
necessary measures and report them in a nonconformity report form (Addendum 2).

1.14 Rules to be followed during operation


In order to prevent direct contamination, SSOPs (Sanification Standard Operating Procedures)
must be put into practice.
Given the type of machine, the SSOP activities regard the routine cleaning of the Automatic Pizza
Vending Machine and taking great care when refilling the machine, with particular reference to:
• the fresh ingredients used for making the pizzas must be procured exclusively from suppliers
who guarantee the wholesomeness of the constituent materials used and the obtaining of
product of a quality that corresponds to contract specifications
• operators must abide strictly by the specifications stated in this manual and in the Use and
Maintenance Manual
• whenever a nonconformity is observed, the person responsible for the HACCP must report it
and complete the form in the addendum.

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

1.15 Supply of constituent materials


• Check the state of hygiene of transport vehicles and the temperatures of refrigerated transport
vehicles
• Before unloading, check the accompanying documents, which must bear the product lot number
(for Traceability purposes)
• Check the expiry date
• Check the state of the packs
• If there are nonconformities, the product must be returned to the sender and reported on a
nonconformity report form (addendum 2)

1.16 Storage of constituent materials


• Keep the different categories of foodstuffs separate
• Keep the products raised up from the floor
• Take care not to damage the packs during handling operations
• Keep to the warehouse and shelves cleaning plans
• Take effective measures against pests and animals (flying and crawling insects, rats etc.)
• Keep to the hygiene and cleaning plan
• Isolate any nonconforming goods in a clearly defined zone in the warehouse, marked with the
notice “DO NOT USE: NONCONFORMING PRODUCTSI” until they are disposed of or returned
to the supplier.

1.17 Swabbing
The effectiveness of the cleaning is confirmed by microbiological tests carried out on different parts
of the machine.
The analyses are done in authorised laboratories.
The results are attached to this manual.
If nonconformities are found, the problem is evaluated and appropriate measures are taken.

1.18 Temperatures
The organoleptic and microbiological qualities of the foodstuffs to be preserved at conditioned
temperatures are maintained if these temperatures are kept under control.

1.19 Prerequisite hygiene requirements


On the machine, a set of prevention activities (prerequisites) have been defined that make it
possible to identify the phases in which hygienic-sanitary hazards for the end user may be
generated.
The following prerequisites are considered:
1. the machine’s hygienic design
2. the management of food products and waste
3. the cleaning of the machine and the work environments
4. the behaviour of personnel
5. supplies.

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

HYGIENIC DESIGN

The hygienic design of the machine and its construction and installation characteristics are
important for the following reasons:
• they guarantee that the foodstuffs are protected against contamination
• they rule out the possibility of the foodstuffs ceding to machine components
• they avoid the build-up of dirt at dead points that are inaccessible for cleaning
• they make cleaning and maintenance easier
• they make access to the machine and its components easier from all sides, including the floor,
and they make it easier to inspect and disassemble
• they exclude the formation of infestations in nooks and crannies, either externally or internally
• they do not keep large quantities of foodstuffs ‘parked’ in the connecting tubing between
components.

FOOD CONTACT AREA


As well as responding to general requirements, the materials used are corrosion-resistant, non-
toxic and non-absorbent. The components in this zone are self-emtpying, with all liquid residues
draining away by force of gravity and not remaining in blind alleys. There are no painted surfaces.

SPLASH AREA
The material requirements and hygienic design are similar to those in the food contact zone,
although less rigorous. There are no painted surfaces. The drive chains are easy to inspect and
disassemble; “non-edible” lubricants can be used.

NON-FOOD AREA
The exposed surfaces are made from corrosion-resistant materials. The surfaces are washable
and, where possible, drain automatically. The motors and gearboxes are designed not to drip oil
from any of their parts.

PRODUCT FLOWS
The components of the machine are connected so that, wherever possible, the process is linear, in
order to avoid cross contamination and product backflow.

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

CONSTRUCTION MATERIALS
The construction materials used for the machine components in the Contact and Splash areas all
comply with binding legislation on contact with foodstuffs.

Inert All surfaces in contact with foodstuffs are inert and compatible, do not yield
surfaces elements from contact with foodstuffs or detergents and disinfectants and do
not transfer bad odours or abnormal colours.
Resistance All surfaces in contact with foodstuffs are resistant to the chemical agents used
in sanitizing, so as to reduce the possible formation of roughness during the
pizza-making process to a minimum.
Joints There are no fixed joints (welded superimposed metal-to-metal) in the product
contact areas; special care has been taken to exclude gaps, hollows, fractures,
protrusions, dead spaces and shadow zones that could jeopardise hygiene
standards. There are no mobile metal-to-metal joins with gaskets or O-rings;
the piping and tubing has been specially routed to avoid the danger of shadow
zones. The connections between rigid and flexible materials have been
designed so that the clamps are as near as possible to the product, to avoid
the creation of interstices that the product can enter.
Fasteners Contact between the product and screw threads and between screws and
supports has been avoided by using external gaskets and fasteners.
Internal The internal edges and corners are designed to allow sanitizing.
edges
Drainage The tanks and tubing are set at an angle (of at least 40°) to guarantee the
outflow of the liquids inside them and to make them easier to empty; where
necessary, plastic tubes are supported to avoid bending. Product contact
surfaces are self-draining.
Insulation The insulation layers (for insulating the refrigerator) have a gasket-free
layers waterporoof coating to prevent the entry of water or product.
Tanks All receptacles containing foodstuffs are insulated externally (with a lid, or
hermetically).

© Copyright Sitos srl November 2008 edition rev. 04 July 2009


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Page 11 of 33
Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

2 SANIFICATION MANUAL
The machine must be cleaned after one week of continuous work. The cleaning and sanitizing
procedure involves the use of hot water, detergents and disinfectants.
The cleaning procedures are described below and must be done by the proprietor of the business
or by the person he/she has appointed as manager (see page 5).

2.1 General cleaning and disinfection procedures


The following rules must be applied:
• put any products safely out of the way
• remove the thick of the dirt
• clean with a tensioactive based detergent, diluted in hot water to the proportions stated on the
label
• rinse with water
• sanitize with a quaternary ammonium salt or chlorine based disinfectant diluted in hot water to
the proportions stated on the label
• rinse with water
• dry
• store the cleaning products and equipment in a designated cupboard
• keep to the specified use concentrations
• choose the right products for the types of surfaces to be cleaned.

2.2 Cleaning
Use the following products for cleaning, depending on the surfaces to be cleaned:
• an ammonia based detergent
• a non-ionic and anionic tensioactive based detergent
• a detergent for hard surfaces with < 5% anionic tensioactive content.

2.3 Disinfection
Use the following products for disinfection:
• chloroactive disinfectant
• quaternary ammonium salt based disinfectant
The cleaning operations are performed on the basis of the methods and times described in the
pages after the forms.

2.4 Personal hygiene


Cuts and skin inflammations must be treated and well protected with waterproof coverings. The
wearing of single-use disposable gloves is obligatory when there are wounds on the hands.
The person responsible for the self-control is also responsible for ensuring that employees observe
the personal hygiene rules stated by law and listed in the enclosed tables.
¾ clothing hygiene: uniforms must be kept in a clean and orderly state
¾ hand hygiene: you must wash your hands frequently during the day:
• after using the bathroom/toilet
• before restarting work
• after handling rubbish
• after touching dirty packaging or surfaces
• after blowing or wiping your nose.

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

2.5 Recommended hand washing procedure

Equipment Products Dilution


Nail brush Emollient sanitizer Pure
Single-use paper

1. Make sure that liquid soap, nail brushes and paper towels are available.
2. Wet your hands and forearms with water at about 45°C.
3. Apply a enough detergent on your hands and scrub to form a sufficient amount of foam and
then scrub and brush your nails, fingers and the backs and palms of your hands vigorously (the
mechanical action of the brush helps the dirt to detach and transfer to the foam).
4. Rinse your hands and forearms with lots of hot water.
5. Take another dose of detergent and wash your hands again, forming lots of foam and scrubbing
particularly thoroughly in the less accessible zones (such as between the fingers).
6. Wash off the foam by re-rinsing with lots of water.
7. Dry with paper towels, then dispose of them in a rubbish bin.

THE HYGIENE OF OUR PRODUCTS


DEPENDS ON THE HYGIENE OF OUR HANDS

Wash your hands:


• Before starting to refill or clean the Automatic Pizza Vending Machine
• after using the bathroom/toilet
• after eating
• when you come into contact with materials not related to the work process.

2.6 Instructions for the correct cleaning of the Automatic Pizza Vending Machine
Clean the vending machine whenever it has been stopped.
Always remember to wash and disinfect the sponges and replace them at least once a month.
If rubber gloves are used, wash and disinfect them after each use.

¾ MIXER
Frequency: a) the mixer must be cleaned after a maximum of one week of continuous work, if
dough that has to be cleaned off is produced every 12h
b) The mixer must be cleaned after 72h if dough that has to be cleaned off is not
produced every 12h.

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Automatic Pizza PRIUS Srl
vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

Equipment Products Dilution


Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Disassemble the mixer cover and whisk
2. Remove any large-size remnants
3. Thoroughly wash the surfaces, cover and whisk with detergent solution and sponge.
4. Rinse with water
5. Spray the sanitizing solution directly on to the components
6. Leave the disinfectant solution to act for at least 10 minutes
7. Rinse
8. Leave to dry
9. Leave the cloths and sponges to soak in disinfectant solution.
10.Reassemble the mixer as described in the User Manual.

¾ HOPPER AND PRE-FORMER


Frequency: weekly.

Equipment Products Dilution


Scraper
Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Disassemble the hopper as described in the User Manual
2. Remove any large-size remnants
3. Thoroughly wash the surfaces with the detergent solution and a sponge
4. Rinse with water
5. Spray the sanitizing solution directly on to the component
6. Leave the disinfectant solution to act for at least 10 minutes
7. Rinse
8. Leave to dry
9. Leave the cloths and sponges to soak in disinfectant solution
10.Reassemble the hopper as described in the User Manual.

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vending HACCP Via Molini, 3
machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

¾ PIZZA CONVEYOR
Frequency: weekly.

Equipment Products Dilution


Scraper
Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Disassemble the pizza conveyor system as described in the User Manual
2. Remove any large-size remnants with a scraper
3. Thoroughly wash the surfaces with the detergent solution and a sponge
4. Rinse with water
5. Spray the disinfectant on the items to be cleaned
6. Leave the disinfectant solution to act for at least 10 minutes
7. Rinse
8. Dry with single-use paper
9. Reassemble the conveyor as described in the User Manual.

¾ PIZZA OUTFEED
Frequency: weekly.

Equipment Products Dilution


Scraper
Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Remove the guard panel positioned between the oven and the pizza outfeed drawer
2. Remove any tomato sauce or cheese remnants from the rear part
3. Thoroughly wash the surfaces with the detergent solution and a sponge
4. Rinse with water
5. Spray the disinfectant on the items to be cleaned
6. Leave the disinfectant solution to act for at least 10 minutes
7. Rinse

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machine HYGIENIC AND SANITARY SELF-CONTROL MANUAL 38027 Malè (TN)

8. Dry with single-use paper


9. Reassemble pizza outfeed drawer guard panel after cleaning and disinfecting it as described in
the User Manual.

¾ INTERNAL SPACES IN MACHINE


Frequency: weekly (parts not in direct contact with food). Especially the tomato sauce zone, the
presser zone and all the guards that catch the pieces of excess food and stop them from falling on to
the other parts of the machine

Equipment Products Dilution


Scraper
Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Remove any large-size remnants with a scraper
2. Thoroughly wash the surfaces with the detergent solution and a sponge
3. Rinse with water
4. Spray the disinfectant on the items to be cleaned
5. Leave the disinfectant solution to act for at least 10 minutes
6. Rinse
7. Dry with single-use paper

¾ TOMATO SAUCE DISTRIBUTOR


Frequency: with every new refill and, in any event. after one week in which there has been tomato
sauce in the machine.

Procedure:
1. Remove the tomato sauce bag and tube
2. Insert a new bag and a new tube.

¾ REFRIGERATOR
Frequency: weekly (bottom of refrigerator).
every three months (refrigerator cabinet).

Before starting, move the goods into another refrigerator.


Switch the refrigerator off before starting the cleaning.

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Equipment Products Dilution


Bucket Hot water As stated on label
Detergent
Sprayer Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Remove any powder and large-size remnants
2. Wash thoroughly, spreading the detergent solution around evenly
3. Rinse copiously with water
4. Spread the disinfectant solution with a sponge
5. Leave the disinfectant to act for at least 10 minutes
6. Rinse thoroughly with water
7. Dry with single-use paper
8. Before reloading the foodstuffs, make sure the operating temperature (4°C) has been reached.

¾ CLEANING THE OVEN AND HOOD


Frequency: every 50/100 pizzas replace the aluminium foil and clean the grill when necessary.
monthly (oven tray, window, hood)

Equipment Products Dilution


Bucket Hot water As stated on label
Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Remove any large-size remnants with a scraper
2. Thoroughly wash the surfaces with the detergent solution and a sponge
3. Rinse with water
4. Spray the disinfectant on the items to be cleaned
5. Leave the disinfectant solution to act for at least 10 minutes
6. Rinse
7. Dry with single-use paper.

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¾ WATER DISTRIBUTION PUMP


Frequency: every three months.

Equipment Products Dilution


Bucket Hot water As stated on label
Detergent
Sponge Chloroactive As stated on label
disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Operate the water distribution pump manually, as described in the User Manual
2. Prepare the disinfectant solution with water and chlorine based disinfectant, diluting as stated
on the label
3. Have the pump draw on the solution and operate it for at least 1 minute
4. Leave the solution in the pump for at least 10 min.
5. Rinse thoroughly with water, running it through the pump as described in the User Manual. Use
drinkable water
6. Reset the pump operating device to automatic, as described in the User Manual.

¾ FLOUR DISTRIBUTOR
Frequency: every three months.

Equipment Products Dilution


Scraper

Bucket Hot water As stated on label


Detergent
Sponge Chloroactive or As stated on label
quaternary ammonium
salt based disinfectant
Single-use paper,
sponge
Single-use gloves

Procedure:
1. Disassemble flour distributor as described in the User Manual
2. Remove any large-size remnants with a scraper
3. Thoroughly wash the surfaces with the detergent solution and a sponge
4. Rinse with water
5. Spray the disinfectant on the items to be cleaned
6. Leave the disinfectant solution to act for at least 10 minutes
7. Rinse

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8. Dry thoroughly with single-use paper, without leaving any damp zones
9. Reassemble flour distributor as described in the User Manual

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3 PART 2: HACCP (HAZARD ANALYSIS CRITICAL CONTROL POINT)

3.1 Hazard analysis and critical control points


HACCP is a preventive control system for foodstuffs that aims to guarantee their safety from primary
production right through to final consumption.
This system makes it possible to identify potential hazards at each step in the production cycle,
evaluate the risks and establish preventive measures to control them by means of the monitoring of
predetermined critical points.
The application of the HACCP system is based on the following stages:

3.2 Preliminary steps


1) Constitution of group
2) Description of product
3) Identification of intended use of product
4) Development of flow diagram

3.3 Principals
1) Analysis of hazards associated to each step
2) Identification of CCPs
3) Determination of critical limits
4) Determination of monitoring systems
5) Determination of corrective actions
6) Documentation management

3.4 Constitution of group


The group is made up of either Mr Taucci Vittorio (head of TCS) or his colleagues, by the head of the
Sitos company, given the qualified and essential role played by the company in the design of the
Automatic Pizza Vending Machine, and by the manager of the machine.
(give first name, surname and name of company)
________________________________________________________________________________
________________________________________________________________________________

The Working Group, as a whole, has knowledge in the following areas:


¾ machine construction technology
¾ work process hygiene
¾ microbiology and chemistry of foodstuffs
¾ quality control techniques and relations with external laboratories
¾ machine construction materials
¾ constituent materials
¾ ingredients, packaging and services
¾ legislation and applicable standards
¾ production planning
¾ system and equipment maintenance
¾ sales organisation.

This Self-control Manual, drawn up by the Working Group, is included with the documents that
accompany each machine.

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3.5 Description of product


The product obtained as a result of the proper use and operation of the machine referred to in this
document is a pizza.
The preparation starts with the mixing of a dry mixture of flour and chemical leavening agents which,
when mixed with water, produce a dough.
This is topped with tomato sauce, cheese, salami and other toppings on request.
The product is then baked in an oven at a temperature of above 300°C.
The product thus obtained comes out of the oven and is positioned on a cardboard tray, ready to be
taken out by the customer.

3.6 Identification of intended use of product


The pizzas are made and baked in just a few minutes, when requested by a customer.
The pizzas, the subject-matter of this HACCP study, are intended for consumption by end users who
use a machine located on a customer’s premises; the HACCP study begins from the moment the
ingredients are loaded and ends the moment the pizza is dispensed to the consumer.

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3.7 Development of flow diagram

1
Choice of APS
components The machine is assembled by qualified
personnel, according to manufacturing
2 Construction instructions and GLP in workshops selected by
of APS
Shipment, transport
SITOS (PRIUS).
3 and installation on
customer’s premises

Cleaning Before starting to produce pizzas, the machine


must be washed as described in the cleaning
4
Cleaning Effluent
Sanitizing and sanitizing section.
Water
5 Taking Taking unused
ingredients ingredients Waste The ingredients are loaded into the various
Ingredients
metering systems by the proprietor of the
Opening
6 containers and
business or his/her designated manager (see
Containers
loading APS page 5). The quantity of ingredients is
calculated to be sufficient for the production of
7 Start APS /
pizza request
100 pizzas.
If any ingredients are left over after the set
8 Dosing flour
time (see the section on cleaning and
and water sanitizing) they must be thrown away in a
rubbish bin.
9
Mixing

When a pizza is ordered, the machine


Preparing pre-
10 formed dough measures out the flour and water into a mixing
and pressing chamber and then forms the dough by stirring
the mixture.
11 Transport

The dough drops down into the pre-former,


12
Dosing tomato
sauce where it is given an initial pressing to form a
semi-finished disk. From here the dough goes
13 Dosing cheese on to the lower presser plate (heated to about
140°C) where it is pressed again to form the
Plastic film
pizza base.
14 Dosing topping
The disc goes under the tomato sauce
metering system that puts a set amount of
15 Baking
sauce on to it.
After this, the topping is measured out.

16
At this point the pizza goes into the oven, stays
Dispensing
Pizza trays
pizza

17
there for about 90 seconds and then, at the
Taking out outfeed, is conveyed and served on a
pizza for end
consumer cardboard tray.

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3.8 Analysis of hazards associated to each step


STEP HAZARD PREVENTIVE CRITICAL TYPE OF FREQUENCY CORRECTIVE TYPE OF CCP
MEASURES LIMITS CHECK OF CHECKS ACTION REPORTING
Receiving Biological and Purchasing from No broken or Visual Each time Non- Nonconformity NO
constituent microbiological: reliable companies soiled packs. inspection. goods are acceptance of report form
materials mould on only. No packs over Check received nonconforming
yeast, animal expiry date. temperature products
infestations Checking of
products directly Clean transport with
Chemical:aflato when unloading. vehicles. thermometer. Verbal report
xins, pesticides to supplier
When unloading the Suitable type of
Physical: goods, the person in transport for
extraneous charge checks the product
material conformity,
cleanness and
temperature of the
transport vehicles.
Preservation Biological and Machine cleaning Correct Check Nonconformity NO
microbiological: and disinfection implementation observance of report form
growth of procedure (see of cleaning SSOP.
pathogens sanitizing manual). plans
Chemical: none Integrity of packs Observance of
Physical: soiled Stock rotation expiry dates
packs Suitable
microclimate
parameters
(T°C and
environment
humidity)
Taking Biological and Withdraw the Temperature of Check Nonconformity NO
ingredients for microbiological: products with the refrigerator observance of report form
loading machine growth of oldest expiry dates rising. SSOP. The
pathogens to allow effective machine has
Chemical: none stock rotation. an automatic
Cleaning and device that
Physical: soiled shuts it down if
packs disinfection
procedures. operating faults
occur in the
Effective personnel refrigerator.
training
Baking Biological and Baking times and Product core Automatic: At each step Eliminate Nonconformity YES
microbiological: temperatures temperature machine nonconforming report form
survival of Correct cleaning >75°C shutdown if products
pathogens and and sanitizing Personnel and oven not
spores procedures machine working.
Chemical: Personnel training hygiene
persistence of
toxins

Dispensing of Biological and Checking of trays on Soiling of Visual Each refill Eliminate Nonconformity NO
pizza on microbiological: receiving: they must packs with new soiled trays report form
cardboard trays cross- be packed in such a trays
contamination. way as to avoid
Chemical: none getting
contaminated by
Physical: soiling
contamination by
pieces of paper

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3.9 Identification of CCPs


The CCPs are identified in the risk analysis and are as follows:
CCP regarding baking and efficient operation of oven

3.10 Determination of critical limits


The critical limits are:

Baking CCP: Product core temperature greater than 75°C

3.11 Determination of CCP monitoring systems


The daily CCP checks are carried out by the person responsible for hygiene and, if problems occur
the machine shuts down automatically.
Any nonconformities and the type of corrective action taken are described by the person
responsible in the addendum. (Addendum 2)

3.12 Determination of corrective actions


The corrective actions to be taken in the event of CCP nonconformities are listed in the table.

CCP Description Corrective action


The machine goes in to an error Machine maintenance
Baking state and pizza production is Completion of nonconformity
stopped report form Addendum 2

3.13 Documentation management


The documentation involves completing the forms in the addendum.
All the forms must be completed and saved so that they can be seen by the officials of the relevant
authorities for possible inspection.

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4 ADDENDA
4.1 Addendum 0: monitoring form
Mark C (conforming) NC (nonconforming)

MON TUES WED THU FRI SAT SUN

Machine
Pre Pre Pre Pre Pre Pre Pre
cleaning

Pre Pre Pre Pre Pre Pre Pre

Personnel

Op Op Op Op Op Op Op

Pre Pre Pre Pre Pre Pre Pre

Environment
on premises

Op Op Op Op Op Op Op

Pre Pre Pre Pre Pre Pre Pre

Toilet
facilities

Op Op Op Op Op Op Op

Pre Pre Pre Pre Pre Pre Pre


Monitoring of
rats, insects,
crawling
animals
Op Op Op Op Op Op Op

Signature

If nonconformities occur, complete the nonconformity report form


(addendum 2).

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4.2 Addendum 1: list of suppliers


The suppliers are those who supply the constituent materials used for refilling the machine, and the
following details must be given about them:
- Company name
- Person in charge of company or contact person
- Address
- Tel., fax, e-mail
- Type of products purchased

Tel.
Company Person in Products
Address Fax
name charge purchased
E mail

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4.3 Addendum 2: nonconformity report form


NONCONFORMITY REPORT FORM

DATE_____________________________________TIME__________________________________

Description of nonconformity______________________________________________________

________________________________________________________________________________

________________________________________________________________________________

SIGNATURE_________________________

Corrective action taken__________________________________________________________

________________________________________________________________________________

Measures taken to prevent reoccurrence of problem____________________________________

SIGNATURE_________________________

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4.4 Addendum 3: plan of premises


(Highlight the area where the machine is located)

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4.5 Addendum 4: results of microbiological swabbing (if performed)


Laboratory tests

Microbiological tests can be conducted with total microbe counts on the foodstuff contact areas to verify the
correct application of foodstuff hygiene procedures.

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4.6 Addendum 5: list of personnel


List of personnel
SURNAME AND NAME
PROFESSIONAL TRAINING
EMPLOYEE
CERTIFIED BY
IN-COMPANY TRAINING
DATE OF EXPIRY DATE:
ISSUE DATE

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Addendum 6: refrigerator control


The refrigerator has an automatic device that shuts down the machine if a cold chain maintenance
anomaly occurs.

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Addendum 7: Techincal details of detergents and disinfectants


Cleaning

Use the following products for cleaning, depending on the surfaces to be cleaned:
• an ammonia based detergent
• a non-ionic and anionic tensioactive based detergent
• a detergent for hard surfaces with < 5% anionic tensioactive content.

Disinfection

Use the following products for disinfection:


• chloroactive disinfectant
• quaternary ammonium salt based disinfectant.

Always take careful note of the use concentrations stated on the labels.
Handle the products with care, and only after reading the safety sheet.

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4.7 List of addenda.


Addendum 0: monitoring form

Addendum 1: list of suppliers

Addendum 2: nonconformity report form

Addendum 3: plan of premises

Addendum 4: results of microbiological swabbing

Addendum 5: list of personnel

Addendum 6: refrigerator control

Addendum 7: Techincal details of detergents and disinfectants used

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