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v10.0
Food Safety
Brand System v10.0 — HACCP Portal
HACCP &
Food
Safety
Monitor. Document. Verify. Protect.
Comprehensive HACCP plan management for GFS facilities. Critical Control Point monitoring, corrective action tracking, prerequisite programs, environmental monitoring, and regulatory audit preparation for Hermitage PA and Edgewood NY operations.
CCPs CAPA SSOPs Audits Env. Mon.
4 CCPs NORMAL AUDIT: 23 DAYS
HACCP Portal
CCPs 4 Monitored
Plans 5 Active (per product line)
Deviations 0 Today
Next Audit 23 Days (USDA)
Facility Hermitage PA / Edgewood NY
H1 Food Safety Dashboard CCPs Monitored, Deviations Today, Corrective Actions Open, Audit Countdown
CCPs Monitored
4 / 4
All within limits
Deviations Today
0
Clear for 14 consecutive days
Corrective Actions Open
2
1 nearing deadline (5/22)
Next Audit
23d
USDA — June 11, 2026
CCP Real-Time Status — Hermitage PA
CCP-1 Pasteurization
Normal
161.2°F
Limit: ≥161°F / 15 sec · Last check: 10:42 AM
CCP-2 Metal Detection
Normal
PASS
Fe: 1.5mm / NFe: 2.0mm / SS: 2.5mm · Last: 10:38 AM
CCP-3 Cold Storage
Normal
36.4°F
Limit: ≤40°F · Continuous monitor · 10:45 AM
CCP-4 Cooking Temp
Normal
205.8°F
Limit: ≥200°F / 2 min (pancakes) · Last: 10:30 AM
■ CCP status refreshes every 60 seconds from facility PLC/SCADA integration. Deviations trigger immediate SMS alert to HACCP team lead and QA manager.
H2 HACCP Plan Management Plan per Product Line, Hazard Analysis, CCP Identification, Critical Limits
Active HACCP Plans
Plan IDProduct LineFacilityCCPsLast ReviewedNext ReviewStatus
HACCP-CHD-001 Barrel Cheddar (40 lb) Hermitage PA CCP-1, CCP-2, CCP-3 2026-03-15 2027-03-15 Current
HACCP-PAN-002 Brown Box Pancakes (144 ct) Hermitage PA CCP-2, CCP-4 2026-02-20 2027-02-20 Current
HACCP-BUT-003 Unsalted Butter (36/1 lb) Hermitage PA CCP-1, CCP-2, CCP-3 2026-01-10 2027-01-10 Current
HACCP-PJS-004 Pepper Jack Sliced (5 lb) Hermitage PA CCP-1, CCP-2, CCP-3 2025-12-18 2026-12-18 Current
HACCP-CCS-005 Cream Cheese Spread (3 lb) Hermitage PA CCP-1, CCP-2, CCP-3 2025-11-22 2026-11-22 Current
Hazard Analysis — Barrel Cheddar (HACCP-CHD-001)
Process Step
Hazard
Severity
Likelihood
Control Measure
CCP?
Raw Milk Receiving
Biological (pathogens)
High
Medium
COA review, temp check
No (PRP)
Pasteurization
Biological (survival)
High
High
HTST ≥161°F / 15s
CCP-1
Salting / Brining
Chemical (excess salt)
Medium
Low
Calibrated dosing system
No (PRP)
Packaging
Physical (metal fragments)
High
Medium
Inline metal detector
CCP-2
Cold Storage
Biological (growth)
High
Medium
Continuous temp monitor ≤40°F
CCP-3
■ HACCP plans developed per USDA FSIS / FDA requirements. CCP determination uses Codex Alimentarius decision tree. Plans reviewed annually or upon process change.
H3 CCP Monitoring Real-Time Log Entry, Deviations Flagged, Corrective Action Triggered
Monitoring Log — Today (May 19, 2026) — Hermitage PA
Time
CCP
Reading
Limit
Result
Operator
Action
10:42 AM
CCP-1 Pasteurization
161.2°F
≥161°F
Pass
T. Santos
None
10:38 AM
CCP-2 Metal Detection
No reject
Fe:1.5mm
Pass
R. Kim
None
10:30 AM
CCP-4 Cooking Temp
205.8°F
≥200°F
Pass
A. Pham
None
10:15 AM
CCP-3 Cold Storage
36.4°F
≤40°F
Pass
Auto
Continuous
09:45 AM
CCP-1 Pasteurization
162.0°F
≥161°F
Pass
T. Santos
None
09:30 AM
CCP-2 Metal Detection
No reject
Fe:1.5mm
Pass
R. Kim
None
Recent Deviation — May 5, 2026 (Resolved)
DEVIATION
CCP-3 Cold Storage · Walk-In Cooler #2 · Hermitage PA
Reading
42.1°F (Limit: ≤40°F)
Root Cause
Door gasket failure on loading dock access
Resolution
Gasket replaced. Product held & evaluated. Released after 2-hr temp recovery.
■ Monitoring frequency: pasteurization every 30 min, metal detection per batch, cold storage continuous. Deviations logged in real time and routed to CAPA workflow.
H4 Corrective Action Log CAPA: Description, Root Cause, Corrective Action, Verification, Preventive Action
Open Corrective Actions
CAPA #DateCCP / AreaDescriptionRoot CauseDue DateStatus
CAPA-2026-018 2026-05-05 CCP-3 Cold Storage Temperature deviation in Walk-In #2 Door gasket degradation 2026-05-22 Verification
CAPA-2026-017 2026-04-28 GMP — Handwashing Soap dispenser malfunction Zone B Pump mechanism failure 2026-05-28 In Progress
CAPA Detail — CAPA-2026-018
1
Description
Walk-In Cooler #2 recorded 42.1°F at 14:22 on 5/5/2026. Critical limit is ≤40°F. Duration of deviation: approximately 45 minutes before detection by continuous monitor alarm.
2
Root Cause Analysis
Door gasket on loading dock access had degraded allowing warm air ingress. Gasket last replaced 18 months ago. PM schedule called for 24-month replacement.
3
Corrective Action
Gasket replaced immediately. All product in Walk-In #2 placed on hold. Temperature recovered to 37°F within 2 hours. Product evaluated by QA — no disposition issues, released for shipment.
4
Verification (Pending)
14-day post-repair monitoring in progress. No further deviations recorded. Final sign-off due 5/22 by QA Manager.
5
Preventive Action
PM schedule updated: door gasket replacement interval reduced from 24 months to 12 months for all cooler/freezer access doors. Added monthly visual inspection to SSOP checklist.
■ CAPA workflow follows FDA 21 CFR 117 / USDA FSIS requirements. All corrective actions require verification before closure. Records retained 2+ years.
H5 Prerequisite Programs SSOPs, GMPs, Pest Control, Sanitation Schedule, Water Testing
SSOPs (8 Programs)
Current
✓
Water safety — Monthly coliform test
✓
Hand/glove contact surfaces
✓
Cross-contamination prevention
✓
Handwashing stations
✓
Adulterant protection
✓
Chemical/compound labeling
✓
Employee health conditions
✓
Pest exclusion
GMPs
Current
✓
Personnel hygiene training (annual)
✓
Hair restraint policy
✓
Jewelry/foreign object policy
✓
Visitor policy & log
✓
Allergen control program
✓
Glass/brittle control
!
Employee refresher due 6/1
Pest Control
Current
✓
Contractor: Rentokil Steritech
✓
Monthly service visit (last: 5/8)
✓
42 bait stations — all secure
✓
18 ILTs — all operational
✓
Trend: 0 rodent activity (6 mo.)
✓
Pest sighting log — clear
Sanitation Schedule — This Week
DayAreaTaskFrequencyAssignedStatus
Mon 5/19 Processing Room A Full CIP + foam sanitize Daily Sanitation Crew A Complete
Mon 5/19 Packaging Lines 1-4 Surface sanitize + verification swab Daily Sanitation Crew A In Progress
Wed 5/21 Walk-In Coolers 1-4 Deep clean + drain sanitize Weekly Sanitation Crew B Scheduled
Fri 5/23 Loading Dock Power wash + perimeter spray Weekly Sanitation Crew B Scheduled
■ SSOPs reviewed quarterly. GMP training renewed annually. Pest control service agreement renewed 1/1/2026. Water testing per EPA standards — municipal supply.
H6 Environmental Monitoring Swab Testing Schedule, Listeria/Salmonella Zones, Trend Analysis
Environmental Swab Zone Map — Hermitage PA
Zone 1
Product Contact
ND
Last: 5/16
Zone 2
Near Contact
ND
Last: 5/16
Zone 3A
Non-Contact
ND
Last: 5/14
Zone 3B
Floor Drains
ND
Last: 5/14
Zone 4A
Loading Dock
ND
Last: 5/12
Zone 4B
Employee Areas
ND
Last: 5/12
ND = Not Detected · All zones testing for Listeria spp., Listeria monocytogenes, Salmonella spp.
Environmental Monitoring Trend — 12 Months
QuarterTotal SwabsZone 1 PositivesZone 2 PositivesZone 3 PositivesZone 4 PositivesOverall Rate
Q2 2025 144 0 0 1 0 0.7%
Q3 2025 148 0 0 0 0 0.0%
Q4 2025 152 0 0 0 1 0.7%
Q1 2026 156 0 0 0 0 0.0%
■ Zones 1-2 sampled weekly, Zones 3-4 biweekly. Positive Zone 1/2 triggers product hold + intensified sampling. Lab: Meritech (3rd party). Results within 48 hrs.
H7 Regulatory Audit Prep FDA/USDA Audit Checklist, Document Gathering, Mock Audit Scheduler
Upcoming Audits
23
Days to USDA FSIS Audit
June 11, 2026 · Hermitage PA
67
Days to SQF Recertification
July 25, 2026 · Hermitage PA
112
Days to FDA Inspection Window
Sept 8, 2026 (est.) · Edgewood NY
USDA FSIS Audit Readiness Checklist
Checklist Item
Status
✓
HACCP plans current for all product lines (5 plans)
Ready
✓
CCP monitoring records complete — trailing 90 days
Ready
✓
Corrective action records with root cause & verification
Ready
✓
SSOP pre-op and operational records
Ready
✓
Environmental monitoring program & trend data
Ready
!
Employee training records — 2 refreshers pending
In Progress
✓
Pest control service reports (12 months)
Ready
✓
Equipment calibration records (thermometers, scales, metal detectors)
Ready
Schedule Mock Audit
Internal mock audit recommended 2 weeks before USDA visit. Next recommended date: May 28, 2026.
■ Audit readiness score: 87% (7/8 items complete). Training gap to be closed by 6/1. Mock audit protocol follows USDA FSIS inspection procedures.
H8 Annual Review HACCP Plan Annual Reassessment, Team Meeting Minutes, Plan Updates
Annual Reassessment Schedule — 2026
PlanProduct LineReview DateTeam LeadTeam MembersStatus
HACCP-CHD-001 Barrel Cheddar 2026-03-15 Dr. J. Morrison (QA Dir.) 5 members Complete
HACCP-PAN-002 Brown Box Pancakes 2026-02-20 Dr. J. Morrison (QA Dir.) 5 members Complete
HACCP-BUT-003 Unsalted Butter 2027-01-10 Dr. J. Morrison (QA Dir.) 5 members Scheduled
HACCP-PJS-004 Pepper Jack Sliced 2026-12-18 Dr. J. Morrison (QA Dir.) 5 members Scheduled
HACCP-CCS-005 Cream Cheese Spread 2026-11-22 Dr. J. Morrison (QA Dir.) 5 members Scheduled
Review Meeting Summary — Barrel Cheddar (March 15, 2026)
HACCP Team Present
Dr. J. Morrison (QA Director, Team Lead)
T. Santos (Production Supervisor)
R. Kim (Sanitation Manager)
A. Pham (Maintenance Supervisor)
M. Levine (CEO / Management Rep)
Key Decisions
1. No new hazards identified since last review
2. CCP-3 monitoring frequency maintained (continuous)
3. Door gasket PM schedule shortened per CAPA-2026-018
4. Environmental monitoring increased for Zone 3 drains
5. Plan approved with minor updates — effective 3/15/2026
■ Annual reassessment required per 9 CFR 417.4. HACCP team includes qualified individuals per Codex guidelines. Minutes archived in document management system with 3-year retention.
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