FLOW CHART- MANUFACTURING OF KHOA

CCP-1
a. Taking Milk into kadhai

b. Boiling of Milk

Evaporation of moisture

c. Desiccation of milk by constant stirring (about 100 rpm)

Change in color & thickened mass

d. Vigorous stirring

OPRP-1 e. Reduce the fire to 80-88ᵒ C

Formation of Khoa showing signs

of sticking together
f. Formation of Khoa showing signs of sticking together

g. Packing

h.Cartooning

i.Storage

j.Dispatch

Formation of Khoa showing signs of

sticking together
 Hazard Analysis Matrix

HACCP Matrix Table

Severity of Consequences
Customer
Customer feels uneasy Health
Major
complaint (Lasts Issues
Likelihood of Occurrence health Death
(No serious during (lasts for
health risk) consumptio issue
3-4 day)
n)

Likelihood Rating 1 2 3 4 5
Very unlikely
(Hasn't occurred 1 1 2 3 4 5
before)
Slight 2 2 4 6 8 10
(Rarely occurs)
Feasible (possible, but 3 3 6 9 12 15
not common)
Likely 4 4 8 12 16 20
(Has before, will again)
Very Likely 5 5 10 15 20 25
(Occurs frequently)

Risk Rating : Minimal Low Medium High Extreme

Likelihood * Severity 1-6 7-10 11-14 15-20 25

A value of above 11 indicates a significant hazard, which would be then controlled by OPRP or CCP. Control measures must be put
in place for these. Hazards that are not significant will have values of 7-10. It is up the Food Safety Team to determine whether it
makes good sense to have any control measures in place to further reduce the risk of the hazard.
 PRPIs this control by
ASSESSMENT OF CONTROL

Severity

Risk Rating
Likely hood
HAZARD IDENTIFICATION Control Measures MEASURES

Score
Flow Chart Hazard type/ A B C D E F G

CTG-CM
Step No./ Description
Name

Physical – presence
of foreign matter in 4 2 8 # Use of clean kadhai & stirrer YES
kadhai
a. Receiving
Chemical – presence
milk into 3 3 9 # Use of non-rusted kadhai YES
of rusting in kadhai
kadhai
Biological- presence
3 CCP-
of pathogens in milk 4 3 12 # Use of fresh milk NO 3 3 1 3 3 1 17
1
imparting sour taste
Physical- chances of
falling foreign # Use of PPEs by workers
matter in the milk # Activity should be carried
4 2 8 YES
from worker & out in well protected
environment environment
b. Boiling of
Milk. Chemical- Not
Likely
Biological- Not
Likely
Physical- chances
c. Desiccation of falling foreign # Use of PPEs by workers
4 2 8 YES
of milk by matter in the milk
constant from worker
stirring (about Chemical – 4 2 8 # Visual check with constant YES
100 rpm) Charring of milk stirring
 Biological – Not
Likely

Physical- chances
of falling foreign # Use of PPEs by workers
3 2 6 YES
matter in the milk
from worker
Chemical – # Visual check with constant YES
3 3 9
d. Vigorous Charring of milk stirring
stirring Biological- Not
Likely
Chemical – Not
likely

Biological- Not likely

Physical- presence
# Use of PPEs by workers
of foreign material 3 2 6 YES
e. Reduce the due to workers
fire to 80-88ᵒ Chemical- Charring # Visual check with constant OPR
4 3 12 NO 3 2 2 1 2 2 1 13
C of material stirring P-1
Biological – Not
Likely
Physical- chances
of falling foreign # Use of PPEs by workers
3 2 6 YES
f. Formation of matter in the milk
Khoa showing from worker
signs of
Chemical- Not
sticking
Likely
together
Biological- Not
Likely
g.Packing Physical- presence 3 2 6 # Use of clean packing YES
of foreign material material
due to packing # Use of PPEs by workers
material & workers
 Chemical- due to # Use of Food Grade packing
non- food grade 3 3 9 material YES
packing

Biological- Not
Likely
h. Cartooning
Physical – Not Likely

Chemical – Not
Likely

Biological- Not
Likely
i. Storage
Physical – Not Likely

Chemical – Not
Likely

Biological- Not
Likely
j. Dispatch
Physical – Not Likely

Chemical – Not
Likely

Biological- Not
Likely
Selection and Assessment of Control Measures
For all the steps , where risk level is above 11, it is considered that these hazards cant be controlled by PRP’s and combination of control measures are selected
based on the hazard analysis, which are capable of preventing, eliminating or reducing food safety hazards to defined acceptable levels.

The control measures selected are categorized as to whether they need to be managed through operational PRP (s) or by the HACCP Plan.

Total Score = (A + B + C + D + E + G )
If the total score is < 14: then the control measures is O-PRP, if the Score is between ≥ 14 then the Control measures is HACCP Plan or CCP

The method and parameters used for the categorization of control measures is described in the below table :

Assessment Criteria for control measures Parameters

a) Control Measures effect on identified food safety hazards relative to the 1- Not eliminate completely
strictness applied 2- Reduce or control to meet acceptable level
3- Reduce to within acceptable
level or eliminate the hazard completely
b) Control measures feasibility for monitoring (e.g. ability to be monitored in a 1. No feasibility
timely manner to enable immediate corrections) 2. Has Limitation
3. Feasible
c) Control measures place within the system relative to other control measures 1. First
2. Middle
3. Final
d) the likelihood of failure in the functioning of a control measure or significant 1. Low
processing variability 2. Medium
3. High
e) the severity of the consequence(s) in the case of failure in its functioning 1. Negligible
2. Complaint
3. Health implications
f) whether the control measures is specifically established an applied to eliminate 1. No
or significantly reduce the level of hazard(s) 2. Somewhat
3. Definitely
g) synergistic effects (i.e. interaction that occurs between two or more measures 1. No
resulting in their combined effect being higher than the sum of their individual 2. Somewhat
effects) 3. Yes