Ijaz Yusuf A Journey of HACCP Certification The Case of ExpressPac Manufacturing & Service Quality Case Study

ICQI-Lahore, 2-3 May 2011
A JOURNEY OF HACCP CERTIFICATION

(The Case of Expresspac)
By
Ijaz Yusuf
Director CSCR, UMT, Lahore
Email: Ijaz.yusuf2002@gmail.com
&
Amjad Naeem
MR, Expresspac
Email m_a_naeem@yahoo.com
ABSTRACT:
ExpressPac is a manufacturer of packaging materials for direct or and indirect use
to food & beverages companies like Unilever, Nestle, Coca Cola, etc so there was
a high demand to build a system that could ensure the issues related to food safety
supply chain. ExpressPac decided to go for first for ISO 9001:2008 certifications
and then for HACCP to overcome the issues associated with food safety and builds
the customer confidence.
No doubt there were many challenges like basic
infrastructure, financial strength, systems expertise, limited staff, trainings lack of

support from the front line managers to achieve this target but there was
commitment of the top management to make this painful journey to a success
story. What are the challenges faced by the company and deployment strategy to
go certifications first for ISO 9001:2008 and second for HACCP. After gap
analysis against HACCP codex, the developed strategy was split in three stages: in
the 1st stage, the common areas of the ISO & HACCP were addressed. In the 2nd
stage, different -requisite programs were established to go before the 3rd stage i.e.
HACCP plan. The stage of HACCP plan is the last control to look down on the
food safety issues that has been filtered by the pre-requisite programs. This paper
attempts to highlight the implementing strategy step by step overcoming the
challenges faced by the company and can be value added input for corporate
world.
Key Words: Quality, Food Safety, HACCP, Certification
INTRODUCTION:
1. HACCP:
It means Hazard Analysis of Critical Control Point. It is the standard to tackle the
food safety issues comprising by the following steps/ stages:
STAGE #: 1
PRE-REQUISITE PROGRAMS
STAGE #: 2
HACCP TEAM
STAGE #: 3 & 4
PRODUCT DESCRIPTION & ITS INTEDED USE
STAGE #: 5
PRODUCTION FLOW DIAGRAM
STAGE #: 6
ON SITE VERIFICATION OF FLOW DIAGRAM
STAGE #: 7 & 8
HACCP HAZARD ANALYSIS WORKSHEET/
DETERMINATION OF CCPs
STAGE #: 9-14
HACCP PLAN SUMMARY
Used Procedure and Formats are given in the Annexure
2. COMPANY:
Contact Information
Company Name
ExpressPac Pvt. Limited
Contact Person
Dr. Muhammad Hussain (CEO) & M. Amjad Naeem (MR)
Company Address
45 Km Multan Road Lahore, Pakistan
Postal Code
55261
Telephone & Fax Number
+92-42-35383477
Mobile Number
0300-8422641
Website
www.expresspac.pk.
Basic Information
Business Type
Manufacturer
Total Area
143500 SFT
Total Covered Area
21895 SFT
Brief Company History/

Milestones
No. of Employees
Business Start up as Express Packaging:.1999

Reorganized as Expresspac (Pvt.) Ltd.: ...2007/ April, 08
Certified for ISO 9001:2008..2010
Certified for HACCP.2010
55 60 People
Employee Facilities
Free Residence & Mess
Products/Services
Stretch Wrap Film

Shrink Wrap Film
Wrapping Film
Lamination Film
Antistatic films & bags
Printing Film
Ghee Film
3-Layer specialized films
Used as primary, 2ndry & tert. packaging material in food
industry) , Hot Melt Wax, CaCO3
Locally working MNCs like:
Our Markets
Nestle Pakistan Ltd; Unilever Pakistan Ltd; Engro Foods Ltd;

Tetrapak Pakistan Ltd; Packages Ltd Lahore; Haleeb Foods
Ltd; ICI Pakistan Ltd; Coca Cola Beverages; Sufi Soap
(Hamza Vegetable Oil); Century Paper & Board Mills;
Shezan International; Riaz Bottleres Lahore (Pepsi); Metro

Cash & Carry; Makro Cash & Carry; Dynamic Packages
(Pvt) Ltd; Al-Aziz Packages Ltd; Converters (Pvt) Ltd; M &
F Commercial; Pack Tech (Pvt) Ltd; Aamir Foods Industries;
Pioneer Pakistan Seed Ltd; Becton Dickinson; Mehboob
Industries (Shan Ghee); Gujranwala Food Industries
ORGANOGRAM:
Organization Chart
Admin
& HR
Sales &
Marketing
Maintenance
Production
QA
&
QC
Lab
Store &
Dispatch
Accounts
/Finance &
Purchasing
OBJECTIVE OF EPL (EpressPac Pvt Limites):

EpressPac Pvt Limites was interested to assure and improve the processes so that
EPL could be selected as a best manufacturer of packaging materials for direct or
and indirect use to food & beverages companies like MNCs and other top
businesses so there was a high demand to build a system that could ensure the
issues related to food safety supply chain. ExpressPac decided to go for first for
ISO 9001:2008 certifications and then for HACCP to overcome the issues
associated with food safety and builds the customer confidence.
PROBLEMATIC AREA:
1. Lacks of basic Infrastructure:
There was a huge need to invest to develop the infrastructure:
Change Over Room

Lockers
Provision of Wash Basin & Hand Dryer in Production Hall
Employee Health Screening
Provision of Additional PPEs for HACCP
Lack of Pest Killers (Glue Pad, Mouse trap & feed, Bait Stations,
Insecticides, Insecticide Spray, Antidermide Spray)
Store Racks
Machines Hoppers Cover
Food grade lubricants
Boards for Hanging SOPs
Sign Boards (Entrance, Exit, etc)
Whitewashing
Machines Paint
Blocking of washroom near Kitchen
External Calibration of Equipment
2. Financial Strength:
No doubt, the company had an interest to compete the market but being a small
unit had not enough resources to fulfill the requirements in few days. But in spite
of being small unit, the management developed the basic infrastructure within the
time.
3. Lack of System Expertise & Awareness:
Although the certification will was continued from the last many years, yet there
was serious lack of system expertise even the routine works were not recorded
properly because of high turnover rate of Management Representative (MR)
4. Purchasing Department & Marketing Department Work:
In these departments, no record was in practice and all the activities related to these
departments were verbal.
5. HR Department & QA Department Work:
No existence of these departments. So the concept like Document & Data
Control, Trainings, System Audits, etc was very weak.
6. Store Work:
There was no record related to stock but when there is a need, the employee was
assigned to count the relevant stock. There was a very difficult to declare that any
item is present in the store although it was available & being purchased before few
days ago. In case of emergency, mostly new purchasing was carried out.
The practical approach to control waste management was very poor i.e. all types of
wastes but all were collected in a way that it becomes difficult either anyone
variety is present or not.
7. Production Department Work:
There were very limited documents Only the Job Card was prepared that contained
the information about PO & Production Status and there was neither process
monitoring, traceability nor proper production record.
8. QC Laboratory:
Only the final inspection of only the film was prepared. The QC department was
just maintaining the record of testing the final product without bothering the results
are OK or not OK. There was consideration when the production results was not
match the customer specified results.
9. Administration Department Work:
Only one register was used to record the said information.
10.Limited Staff: Purchasing Department:
Not well defined, all the three CEO and two Directors including Maintenance
Incharge were involved in purchasing.
11.Limited Staff: Marketing Department:

The CEO himself along with one more employee that left the company in early
days of certification preparation was running this department.
12.Limited Staff: HR Department:
As there was no existence of the HR department, so there was no any employee to
execute the HR related functions.
13.Limited Staff: QA Department:
There was a vacancy but the appointed employee was responsible to do the QC
activities. The company was at a first stage of preparing Quality Manual through
Deputy General Manager.
14.Limited Staff: Store:
No regular employee was appointed in store. CEO, production department and
maintenance department were jointly running the store.
15.Limited Staff: QC Department & Production Department:
The strength of these departments was as required.
16.Lack of Support from Front Line Managers
As there was lack of staff and the employees had no awareness about the
management systems so they were terrified to do the work in this style.
17.No Hierarchy System
Every employee was considered to responsible for every business activity but no
one was answerable.
18.High Turnover:
At the management level, the turnover was controlled but at the operator level the
turnover was absolutely unsatisfactory that was causing to train the employees
frequently and ultimately it becomes difficult to achieve the implementation targets
successfully.
19.Resistance to Change
As there is a human nature that they resist the change because it is a quite new
imitative for a packaging industry so that is why people resist the change and
create hurdles for implementation.
20.Company Culture
The company was initially a one man show the man who took lot of pain to create
this business kingdom. People are used to listen and obey the verbal orders.
Documentations, written policies and the officer memos are not the part of
company culture. It was very difficult to change the people from individual focus
to system focus.
21.Reluctance to Acquire New Skills
Most of the employees belong to rural areas and they are reluctant to learn the new
skills. They focus only to the primary function but to learn quality related
education was not their main focus.
22.Lack of Support from Front Line Managers
Line managers and executives want to make the place in the eyes of top
management so they do not encourage the Quality staff to ponder in their areas and
share the information with the top management that is why they do not extend the
support to HACCP Team involved in HACCP activities.
WORKING METHODLOGY:
Along with the resolution of the above mentioned problematic Issues, there was a
need to cover all the steps required for certification starting from documentation to
certification including to build a team that is capable to achieve certification target
successfully.
To resolve the problematic Issues and to kill down the issues of Lacks in Basic
Infrastructure & Financial Strength, carefully, financial targets were also
achieved. The financial strength was not resulted more problems because there is a
need of enough time to build the structure.
To kill down the issues of High Turnover, Lack of System Expertise &
Awareness & Lack of Support from front Line Managers, much training were
conducted about System, Culture and Motivation. 5S system was introduced for
best Store Management related to both Raw & Finished. Further the waste store
was separated along with partition so that problems produced in formulation
creating by the improper waste management could be resolved.
To kill down the issues of Limited Staff, the work has been done more than 8
hours by following the principles of Hard & SMART working.
To kill down the issues of No Hierarchy System, proper hierarchy was approved.
To Document, Implement & Certification:

For this purpose, the following steps were carried out:
Phase-I: Gap Analysis for ISO 9001:2008

Phase-II: Departmentalization/ Hierarchy Development
Phase-III: Each Department Documentation Structure
Phase-IV: Training about System
Phase-V: Implementation
Phase-VI: Internal Audit
Phase-VII: Certification for ISO 9001:2008
Phase-VIII: Gap Analysis for HACCP
Phase-IX: Align 9001 with HACCP
Phase-IX: Developed PRPs

Phase-IX: Implemented PRPs
Phase-X: Improve through Internal Audits
Phase-XI: Developed HACCP Plans
Phase-XII: Implementation
Phase-XIII: Internal Audit
Phase-XIV: Certification for ISO 9001:2008
DEPLOYMENT STRATIGIES:
First to implement ISO 9001:2008 and then HACCP
Expel out the Non-Supporting Employees
LITERATURE REVIEW:
In literature and corporate world many food safety initiatives like Global Food
Safety Initiative (GFSI), Hazard Analysis for Critical Control Points (HACCP),
Good Manufacturing Practices (GMP), Safe Quality Food (SQF), British Retail
Consortium (BRC), Food Safety Management System (ISO 22000) and American
Institute of Baking Standard (AIB Standard) exist. A representation of common
ground between food safety schemes was needed to enhance food safety, ensure
consumer protection, and to strengthen consumer confidence.
To address these needs, the Global Food Safety Initiative (GFSI) was coordinated
and launched in May 2000 by CIES--The Food Business Forum, an independent
global food business network headquartered in Paris. Founded in 1953, CIES has
developed numerous programs for retailers and supply chains, and continues to
facilitate the development of common positions and tools on strategic and practical
issues affecting the food business. CIES shares best practices throughout 150
countries.
The GFSI is a nonprofit foundation created under Belgian law with a mission to
work on continuous improvement in food safety management systems to ensure
confidence in the delivery of food to consumers.
The GFSI guidance document was developed for guidance and to set commonly
agreed criteria as a framework to which food-safety-related schemes can be
benchmarked. It is not a standard and GFSI is not involved in certification or
accreditation activities.
Currently in its fifth edition, the guidance document provides the procedure for
benchmarking of food safety management schemes, the key elements for the
production of food within a conforming food safety management standard (i.e.,
good manufacturing practices, or an HACCP program or equivalent system ), and
guidance on the certification processes of a food safety management system.
The GFSI guidance document is freely available on the CIES web site
(www.ciesnet.com).
Currently there are four food safety standards formally benchmarked to GFSI.
They are the British Retail Consortiums (BRC) Global Standard for Food Safety,
the International Food Standard (IFS), the (Dutch) National Board of Experts
Hazard Analysis and Critical Control Point (NBE HACCP) Option B, and the Safe
Quality Food (SQF) 2000 Code. (11)
Hazard Analysis Critical Control Point Systems (HACCP)

In the 1960's, NASA wanted to guarantee that the food for astronauts on space
flights was totally safe. The task of producing "Zero Defect" food was contracted
to the Pillsbury Corporation who developed the first system of Hazard Analysis Critical Control Points or HACCP (16). In 1995, HACCP was instituted in the
seafood industry and monitored by FDA. The HACCP idea is now becoming the
standard throughout the entire food industry. HACCP is based on the identification
and control of physical, chemical and biological hazards. The goal of HACCP is to
control and prevent the contamination of the food products. The reasoning for
HACCP implementation are 1stly it demonstrate and documents a commitment to
deliver safe food products to consumer, 2ndly a HACCP program also helps make
food processing more efficient and less costly in the long run and 3rdly FDA and
USDA become more involved in food safety, and in particular HACCP, more
regulations will be issued.
Physical
Chemical
Biological
Bone
Acids
E.Coli 0157:7
Metal
Solvents
Salmonella
Wood
Sanitizer
Staph. Aureus
Rubber
Pesticides
Lister Monocytogenes
Glass
Lubricants
Shigella
Rodent
Caustics
Cryptosporidium
Plastic
Sulfites
Campylobacter
Stone
Allergens
Yersinia Enterocolitica
Hair
Aflotoxin
Bacillius Cereus
Paper
Hapatitis A
(28)
HACCP is Hazard Analysis and Critical Control Points Principles that focus
attention on food safety at every step of the journey from the farm to the
consumer's table (19). Prerequisite programs such as current Good Manufacturing
Practices (GMPs) are an essential foundation for the development and
implementation of successful HACCP plans (20). HACCP significantly reduces
the risk of food contamination in two ways: First, it anticipates potential problems
or failures and does not depend only on a final inspection. Second, because it
identifies problems during the process rather than at the end of the process or once
the product moves into the supply or marketing chain there is a greater likelihood
of resolving the problem at hand as opposed to pursuing a product recall (16). Its
importance is first in the U.S. HACCP has become a legal requirement for the
fish, poultry and meat industries (16), and 2ndThe proactive HACCP Food Safety
Management System is based on the CODEX Alimentarius Commission
adaptation of the FAO/WHO Guide or guidelines for application of the Hazard
Analysis Critical Control Point system, which is by far the most internationally
recognized safety and quality assurance system for all food related industries
directly in the food chain (26).
Good Manufacturing Practices (GMP)
Good Manufacturing Practices (GMP) direct all persons working in direct contact
with food, surfaces that food might contact, and food packaging materials, to
conform to sanitation and hygiene practices to the extent necessary to protect

against contamination of food from direct or indirect sources (16).
Safe Quality Food (SQF):
The SQF Program (Safe, Quality Food) is one of the world's leading food safety
and quality management systems, designed to meet the needs of retailers and
suppliers worldwide. The Program provides independent certification that a
supplier's food safety and quality management system complies with international
and domestic food safety regulations. This enables suppliers to assure their
customers that food has been produced, processed, prepared and handled according
to the highest possible standards, at all levels of the supply chain.
SQF is designed as a food safety program, but it also covers product quality,
assuring consistent quality and meeting buyer specifications. The SQF Program is
administered by the SQF Institute (SQFI),
McDONALDS-AUDIT-V-1-0-AUG1210SQF-ETHICAL-SOURCING-V-1-0
SQF2000-DOC-LEVEL-2-VER-2-0
SQF2000-DOC-LEVEL-3-VER-2-0
SQF2000-FAC-LEVEL-1-VER-2-0
SQF2000-FAC-LEVEL-2-VER-2-0
SQF2000-LEVEL-3-FAC-VER-2-0
Rpt300AuditChecklistSQF 1000 document level 2 v1 (22)
SQF 1000/2000
The SQF Program is an internationally recognized comprehensive food safety and

quality management system to cover the entire food chain from farm to fork.
The Program is made up of two codes (standards), the SQF 1000 Code for the
primary production sector and the SQF 2000 Code for the food manufacturing and
service sectors. Suppliers can implement a management system which meets any
of the following three levels of certification:
Level 1: Food Safety Fundamentals: Indicates that pre-requisite programs and

fundamental food safety controls have been implemented to provide a sound
foundation for the further development of the suppliers management system.
Level 2: Certified HACCP Food Safety Plans: Incorporates all Level 1 system
requirements, and indicates that a food safety risk assessment of the product and its
associated processes has been completed. This assessment must identify the
hazards and the actions taken to eliminate, prevent or reduce their occurrences.
Level 3: Comprehensive Food Safety and Quality Management System:
Incorporates all Level 1 and Level 2 system requirements, and indicates that a food
quality risk assessment of the product and its associated process has been
completed. Additionally, at Level 3 an organization must show that the actions
taken to prevent the incidence of poor quality have been implemented and that the
remaining quality management system procedures addressed in the standard have
been implemented. (9)
The SQF 2000 Code is designed for use in all sectors of the food industry as a
HACCP-based quality management system to reduce the incidence of unsafe food
reaching the marketplace. It is a food safety program that also covers product
quality. It offers benefits to suppliers and buyers at all links in the food supply
chain by addressing the buyers food safety and quality requirements, and provides
a solution for the suppliers.
First launched in 1994, The Food Marketing Institute acquired the rights to the
SQF program in 2003 and established the SQF Institute (SQFI) division to manage
the program. Now in its sixth edition, SQF 2000 Code is recognized by GFSI as
meeting its benchmark requirements. It is the only GFSI-recognized certification
system that links primary production certification to food manufacturing,
distribution, and agent/broker management certification.
The program provides independent certification that a suppliers food safety and
quality management system complies with international and domestic food safety
regulations. This enables suppliers to help assure their customers that food has
been produced, processed, prepared, and handled according to the highest possible
standards, at all levels of the supply chain.
Levels of certification
The SQF 2000 Code is divided into three certification levels: Level 1 covers food
safety fundamentals; at Level 2, certified HACCP food safety plans are recognized
by GFSI; and at Level 3, comprehensive food safety and quality management
system actions exceed the GFSI benchmark requirements.
The SQF program has many unique features that help ensure trust and consistency
in the auditing process. Certification bodies that are licensed by the SQFI to
perform SQF audits are subject to regular assessments of their certification and
audit activities by internationally recognized accreditation bodies licensed by
SQFI. Auditors are only permitted to perform audits in the food industry sectors
for which they have been registered, and in which they have extensive expertise
and experience. (11)
The BRC (British Retail Consortium)
The BRC (British Retail Consortium) Global Standard for Food Safety was created
to ensure supplier compliance and secure retailers ability to guarantee the quality
and safety of the food products they sell. Today it is used worldwide as a
framework for any business (retailers and processors) to assist the production of
safe food and the selection of reliable suppliers.
It helps companies to select and qualify their suppliers. In other words it is going to
be accepted by the majority of food retailers as equivalent to the other
benchmarked food safety standards, such as IFS, SQF and the Dutch HACCP (22).
The BRC Global Standard for Food Safety is an accredited, certifiable standard,
and the first one to be approved by GFSI in 2000. The principles of the BRC
Global Standard for Food Safety are based on two key components: senior
management commitment and HACCP. (11)
BRC Global Standard Packaging
Issue 2 of the BRC Global Standard - Food Packaging and Other Packaging
Materials
Content of the Standard
The standard consists of eight sections plus an associated protocol. Each section
sets out a statement of intent and all packaging suppliers will need to comply with
this statement in order to gain certification.
1. Scope
General overview of the standard, who the standard applies to and what the
requirements of the standard are.
2. Organization
Covers the requirements for the organization in terms of management
responsibility, organizational structure and management review.
3. Hazard and risk management system
Covers the requirements for a formal hazard analysis of the production process
considering foreign object, chemical and microbiological contamination as well as
packaging defects that compromise consumer safety.
4. Technical management system

Covers the quality and hygiene policy, hygiene system documentation and control,
specifications, management of incidents and product recall, traceability system,
internal audits, complaints, supplier monitoring, subcontracting and product
analysis.
5. Factory standards
Covers the requirements for the building infrastructure, facilities and fabric,
product flow, maintenance of equipment, housekeeping, cleaning and waste
management.
6. Contamination control
Covers the requirements for foreign object training, glass control, blade control,
chemical and biological control, pest control and transport, storage and
distribution.
7. Personnel
Covers the access and movement of personnel, staff facilities, toilets and hand
washing, eating, drinking and smoking, illness and injury, jewellery and personal
items, protective clothing and hygiene training.
8. Risk category determination
In this section the supplier uses the decision tree to determine whether they are a
category A or B risk supplier. (8)
ISO 22000
The food safety management system standard ISO 22000 enables any company
directly or indirectly involved in the food chain to identify the relevant risks and
manage them efficiently.
Implementation of a food safety management system compliant with the ISO
22000 standard changes your companys approach from retroactive quality testing
to a preventive way of thinking (22).
The ISO 22000 food safety management standard incorporates the following
elements:
Interactive Communication
System Management
Prerequisite Programs
HACCP Principles (12)
The ISO 22000 standard delivers a common global framework of safety
requirements for all organizations in the food supply chain, including crop
production, processing, distribution, and related operations. It is an international
standard that harmonizes various existing national and industry certification
schemes.
ISO 22000 incorporates all seven of the contemporary HACCP principles and
implementation plans. Overall, ISO 22000 creates an effective framework for food
safety management, communication along the food supply chain, and control of
food safety hazards. (11)
Food Safety Management Systems: ISO 22000 or FSSC 22000?
The ISO 22000 scheme and the FSSC 22000 scheme differ slightly. ISO 22000
Certification applies to all organizations in the food chain (i.e. all including from
the farm to the food packaging producer. FS22000 Certification applies only to
food manufacturers, and is recognized by the Global Food Safety Initiative, GFSI.
The FSSC 22000 scheme requirements are made up of the ISO 22000:2005
standard and one more document, the PAS 220:2008 published by BSI and
specifying detailed PRP requirements for manufactures in the food industry.
There has been an abundance of food safety standards in the world, but there is
also variation between standards, their implementation and auditing. With the
success that the International Organization of Standardization (ISO) has with
harmonization of standards, it was logical that they take on this issue with the
development of an ISO Food Safety Standard. The standard, ISO 22000 was
released in 2005. Since its release it has been successfully implemented in
hundreds of companies around the world. The ISO 22000 Standard can be applied
to any organization in the food chain, from the farm to the food packaging
producer.
However, the Global Food Safety Initiative is another organization playing an
important role in Food Safety Systems. This organization has "benchmarked" four
existing food safety schemes. Once a system is "benchmarked" it means that
certification to the scheme is accepted by organizations requiring a GFSI scheme.
The current list of GFSI schemes includes IFS, SQF, BRC and Dutch HACCP
(14).
After searching the web (including opinions on this site), it led me to believe that
there is little difference between many of the standards. As a matter of fact, it
seems most of them are starting to look more the same after each revision.
Similarities:
All identify PRPs as critical (with some varying degree of application)
All use HACCP as a base
All require some level of document/record control
All require a commitment to food safety
The main difference thus far is that SQF, AIB, BRC, IFS et al. are prescriptive
standards whereas ISO 22000 is a management system standard and encourages
the user to join up the dots.
The Global Food Safety Initiative (GFSI) goal is to benchmark all major food
safety standards so that any and all are accepted throughout the world. A worthy
cause but not an easy task. GFSI has so far approved:
- BRC Technical Standard
- Dutch HACCP Option B
- International Food Standard
- SQF 2000
This "new" Dutch HACCP aims a better position than ISO 22000 at the moment.
It's a good solution for organizations who wants to meet the GFSI standards with
one assessment. (2)
PRE-CERTIFICATION AUDIT:
Two audits were conducted and while auditing it was, cared that there is a next
audit of certification. Few major and minor non-conformances are highlighted
which was closed before the final audit.
CERTIFICATION AUDIT:
If there is will/ commitment of employees and top management & minimum
proficiency to do the specific job, then results are certainly happened.
By the Grace of Allah there was no major non conformance and we got the
HACCP Certification.
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28. Hazard Analysis of Critical Control Points, Workbook by Markson, Inc.-800-528-5114
29. Syed, Tauqeer Haider (1995) TQM via ISO 9000 CDL Experience Pakistan sIst
International Convention on Quality Control, Karachi 1995
30. Hussain, Asif (1996) Implementing ISO 9000/CGMP in Surgical Industry Pakistans
Second International Convention on Quality Control, Karachi 1996
ANNEXURES
ANNEXURE -1:
PRE-REQUISITE PROGRAMS:
Procedure-1:
Records:
Establishment: Design & Facilities

1-Factory Layout
2-Some Basic Factory Information
Procedure-2:
Records:
Glass Management & Hygiene Control System

1-Inspection report for management of glass;
2-Sanitizing Solution Concentration Record;
3-Discarded Product Record
Procedure-3:
Records:
PRP-Store Management
1-Checklist for Receiving Goods
2-Checklist for Finished Goods
Procedure-4:
Records:
PRP-Product Recall
1-Recall Team
2-Recalled Product Trace back Log
3-Recall Notification
4-Recalled Product Distribution
5-Recalled Product Corrective Action)
Procedure-5:
PRP-Cleaning & Sanitizing
Procedure-6:
PRP-Pest Control
Records:
1-Type of Pests & their Control

2- Functional Report of Pest Control Equipment
3-Pest Control Equipment Log Book
4-Spray Log Sheet
5-Observed Non-Captured Pest Log Book
Procedure-7:
Records:
PRP-Monitoring Effectiveness
1-Pre-Operational Inspection Checklist
2-Monthly Maintenance Checklist
Procedure-8:
Records:
Procedure-9:
PRP-Health Screening
1-Health Screening Report
PRP for Reporting Employee Illness & Injury
Records:
1-Reporting Employees Illness & Injury
Procedure-10:
PRP-Hand washing
Procedure-11:
PRP-Personal Hygiene
Records:
1-Checklist of Personal Hygiene Facilities
Procedure-12:
PRP for Visitors
Records:
1-Visitors Log Book
Procedure-13:
PRP-Incoming Vehicle Inspection
Records:
1-Transport Contract
2-List of Contractors
3-Incoming Vehicle Inspection Checklist
Procedure-14:
PRP-Product Information & Consumer Awareness
ANNEXURE -2:
HACCP TEAM
Name
Coordinator
Position
Management Representative
CEO
Account & Purchase Manager
Other Team Members
Maintenance Incharge
Production Incharge
Admin. & HR Officer
HACCP SUB TEAM

Name
Designation
Specialty in Hazard Type
CEO
Microbiological & Chemical Hazard
Physical Hazard
Production Incharge
Physical Hazard
ANNEXURE -3:
PRODUCT DESCRIPTION & ITS INTEDED USE FOR FILM
PRODUCT
NAME
IMPORTANT
PRODUCT
PROPERTIES
Friction
Extrusion
Process
WHITE
OPAQUE
FILM
LDPE based
Sealing
HOW IT
IS TO BE
USED
PACKAGING
&
LABELLING
SHELF LIFE &

STORAGE
CONDITIONS
Ready to
use as a
primary
packagin
g
material
for
laminati
on of
tea bags,
shampoo
bags, etc
1 year Shelf
Life
Only stretch
< 300C
wrapping for Storage
rolls < 50 Kgs Temperature
and Card
Away from
board along Sunlight
with stretch
wrapping for
rolls > 50 Kgs
WHERE
IT WILL
BE SOLD
CONSUMER
INSTRUCTION
SPECIAL
DISTRIBUTION
CONTROL
M&F
Pak
Packages
Dynamic
Al-Aziz
Acclimatize for
24 hours before
use or increase
uses temperature
to get the
desired
performance
Appropriate
vehicle
ensuring safety
from any
physical,
chemical or
biological
hazard
contamination
ANNEXURE -4:
PRODUCTION FLOW DIAGRAM FOR POLY BAG
Unloading of material from the vehicle while stacking in the Store
Carry the required material for the assigned job with the help of lifter
Take the material in the tub according to recipe and then
transfer to m/c hopper after mix it manually
The material passes through extruder, connector & then die in the form of bubble.
And the bubble is maintained with the help of the air provided through the
compressor.
Wrap the reel with stretch wrap
Transfer the tube towards bag making machine with the help of lifter
Load and pass the tube through the guiding rolls
Pass the film under the sealer
Pass the film through the guiding rolls
Cut the film with the help of cutter
Pack the bags
Transfer the bag for weighing & then stacking on the
pallets present in the stacking area with the help of lifter
Cover the bags with the poly film
Dispatching of material to customer through the contractor van
ANNEXURE -5:
ON SITE VERIFICATION OF FLOW DIAGRAM
Name
Designation
CEO
Management Representative
Production Incharge
Admin. & HR Officer
Signature
ANNEXURE -6:
Physical
Biological
Is this step a critical

control point? (y or n)
Chemical
Are the potential

hazards, at this step
have been controlled or
enhanced by the PRPs
What control measures

can be applies for the
significant hazard?
Biological
Risk Level
If the air to
maintain
the size of
the bubble
& passage
from die to
winding
roll is not
clean
Due to
Diseased
Personnel
There is no
prerequisite
available
Uncontrolled
CCP
PRP for
Personnel
Hygiene,
Reporting
of Illness &
Injury, &
Health
Screening
are
available.
Controlled
Contaminat
ion due to
Improper
caring
while
packing the
reel
PRP of
Glass
manageme
nt &
Hygiene
Control
System and
store
manageme
nt are
available.
Controlled
Justify your
determination of
hazard significance
Are any potential food

safety hazards
significant? (y or n)
The material
passes through
extruder,
connector & then
die in the form of
bubble. And the
bubble is
maintained with
the help of the air
provided through
the compressor.
Identify potential
Hazards introduced,
controlled, or
enhanced, at this step
Processing Step
HACCP HAZARD ANALYSIS WORKSHEET:
Wrap the reel

with stretch wrap
Chemical
Physical
N
Y
ANNEXURE -7:
HACCP PLAN SUMMARY
Process
Steps /
CCP
Fill the
bubble
with air
to attain
the
required
size
Hazard
Dust
Critical
Limits
Dusty
Air
Filters
Monitoring Procedures
What
How Freq.
Who
Inspection
of the Air
Filter
Corrective
Action
Verification
Record
Keeping
1-CCP
under
control;
2Disposition
of noncomplying
Maintenance
Daily
product;
Incharge
3-Caused
corrected
to prevent
a
recurrence;
4-Maintain
the record
1-Area
Clean &
Maintained;
2-Personal
Trained; 3Critical
records
accurate &
maintained
1-All
verification
records;
2-All
critical
factors
Recording
Acknowledgement:
We are thankful to Mr. Muhammad Hussain PhD CEO Express Pac (Pvt)
Ltd. who allowed us to share the data of ExpressPac to other companies as a
best management practice.

Ijaz Yusuf A Journey of HACCP Certification The Case of ExpressPac Manufacturing & Service Quality Case Study

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ICQI-Lahore, 2-3 May 2011

A JOURNEY OF HACCP CERTIFICATION

No doubt there were many challenges like basic

infrastructure, financial strength, systems expertise, limited staff, trainings lack of

ICQI-Lahore, 2-3 May 2011

Key Words: Quality, Food Safety, HACCP, Certification

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ExpressPac Pvt. Limited

Dr. Muhammad Hussain (CEO) & M. Amjad Naeem (MR)

45 Km Multan Road Lahore, Pakistan

Telephone & Fax Number

Total Covered Area

Brief Company History/

Business Start up as Express Packaging:.1999

Free Residence & Mess

Stretch Wrap Film

Nestle Pakistan Ltd; Unilever Pakistan Ltd; Engro Foods Ltd;

ICQI-Lahore, 2-3 May 2011

Shezan International; Riaz Bottleres Lahore (Pepsi); Metro

OBJECTIVE OF EPL (EpressPac Pvt Limites):

ICQI-Lahore, 2-3 May 2011

Change Over Room

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

11.Limited Staff: Marketing Department:

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

To Document, Implement & Certification:

ICQI-Lahore, 2-3 May 2011

Phase-I: Gap Analysis for ISO 9001:2008

Phase-IX: Align 9001 with HACCP

Phase-IX: Developed PRPs

Phase-X: Improve through Internal Audits

Phase-XI: Developed HACCP Plans

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

Hazard Analysis Critical Control Point Systems (HACCP)

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

conform to sanitation and hygiene practices to the extent necessary to protect

The SQF Program is an internationally recognized comprehensive food safety and

ICQI-Lahore, 2-3 May 2011

Level 1: Food Safety Fundamentals: Indicates that pre-requisite programs and

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

4. Technical management system

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

ICQI-Lahore, 2-3 May 2011

Establishment: Design & Facilities

Glass Management & Hygiene Control System

PRP-Cleaning & Sanitizing

1-Type of Pests & their Control

2-Monthly Maintenance Checklist

ICQI-Lahore, 2-3 May 2011

1-Reporting Employees Illness & Injury

1-Checklist of Personal Hygiene Facilities

PRP for Visitors