Professional Documents
Culture Documents
SPS
AUTOMATIC
PIZZA VENDING MACHINE
HACCP
MANUAL
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
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.
___________________________ _______________________________
SSOP
• 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.
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.
1.10 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.
• 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. 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).
1.17 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.
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.
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.
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).
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).
2.2 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.
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.
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.
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.
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.
¾ PIZZA CONVEYOR
Frequency: weekly.
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.
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
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
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).
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.
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.
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.
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
8. Dry thoroughly with single-use paper, without leaving any damp zones
9. Reassemble flour distributor as described in the User Manual
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
This Self-control Manual, drawn up by the Working Group, is included with the documents that
accompany each machine.
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
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.
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
4 ADDENDA
4.1 Addendum 0: monitoring form
Mark C (conforming) NC (nonconforming)
Machine
Pre Pre Pre Pre Pre Pre Pre
cleaning
Personnel
Op Op Op Op Op Op Op
Environment
on premises
Op Op Op Op Op Op Op
Toilet
facilities
Op Op Op Op Op Op Op
Signature
Tel.
Company Person in Products
Address Fax
name charge purchased
E mail
DATE_____________________________________TIME__________________________________
Description of nonconformity______________________________________________________
________________________________________________________________________________
________________________________________________________________________________
SIGNATURE_________________________
________________________________________________________________________________
SIGNATURE_________________________
Microbiological tests can be conducted with total microbe counts on the foodstuff contact areas to verify the
correct application of foodstuff hygiene procedures.
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
Always take careful note of the use concentrations stated on the labels.
Handle the products with care, and only after reading the safety sheet.