Unipex Dairy Products Co. Ltd.

;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
$.0" Good Manufacturing Practice:
GMP (Good Manuf act uri ng Pract i ce) i s basi c requi rement of any f ood f act ory. I t i s
a gui del i ne f or f ood est abl i shment s governi ng personnel requi rement s, hygi ene,
sani t at i on and f ood handl i ng pract i ces.
Personnel:
At ni pe! "e have gi ven basi c f ood hygi ene t rai ni ng t o al l our #ey "or#men
"ho handl e t he f ood product or "ho "or#s i n such a pl ace t hat hi s pract i ces
may af f ect t he product saf et y.
Personnel H%gi ene
Al l personnel t hat come i nt o cont act "i t h f ood are mai nt ai ni ng a hi gh st andard
of personal hygi ene.
$and "ash st at i ons are i nst al l ed at al l ent rances t o process areas and t hei r
use i s enf orced each t i me personnel ent er and l eave t he product i on area. %hey
are regul arl y mai nt ai ned and cl eaned t o #eep t hem i n good "or#i ng order.
&l ect roni c eye operat ed ('on (ont act ) t aps are used t o prevent hand cont act .
$and di si nf ect ant di spensers are si t ed cl ose t o t he product i on l i ne t o al l o"
addi t i onal rapi d hand di si nf ect i on and good qual i t y di sposabl e paper t i ssues
are made avai l abl e at al l t he t i me.
%he use of di sposabl e pl ast i c or rubber gl oves gi ve some prot ect i on "here
product i s handl ed but t he gl oves are changed "henever t hey become damaged
) soi l ed. I t i s made cl ear t o al l "or#men t hat t he "eari ng of gl oves does not
mean t hat personnel may f reel y handl e cont ami nat ed i t ems of pl ant , or t hat
regul ar hand "ashi ng i s not necessary.
Product i on personnel are gi ven cl ean "hi t e prot ect i ve cl ot hi ng* s "hi ch are
changed regul arl y. +i sposabl e pl ast i c aprons are al so #ept at ent rance t o
have more prot ect i on .
Prepared "y #ssued "y ppro$ed "y Pa%e & o' 6


Unipex Dairy Products Co. Ltd.;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
Pract i ce of coveri ng $ai r and beards i s i n pl ace t o avoi d any ent r y i nt o product
by f al l i ng l oose hai r f rom "or#men.
Al l empl oyees are t rai ned t o ensure t hat t here i s no eat i ng, dri n#i ng or smo#i ng
i n product i on area and no "at ches or , e"el l ery shoul d be "orn.
Gl ass"are* s are not carri ed t o product i on area.
-ashroom f aci l i t i es can act as sources of cont ami nat i on and so i t i s al "ays
#ept cl ean. Post ers are f i t t ed t o remi nd personnel t o "ash t hei r hands bef ore
re.ent eri ng process areas.
&ngi neers and mai nt enance personnel are t rai ned t o "or# i n product i on area.
Mai nt enance personnel are adheri ng t o t he hygi ene rul es appl i cabl e t o
product i on personnel .
I f t he person i s f eel i ng si c# "hi l e on dut y or at home, he "i l l report t o shi f t
e!ecut i ve and shi f t e!ecut i ve "i l l t a#e f urt her requi red act i on t o send hi m t o
hospi t al , af t er recoveri ng he "i l l come up "i t h doct or * s report s. /eport s are
mai nt ai ned.
MANAG&M&NT:
&ff ect i ve management of bot h personnel and processes i s absol ut el y essent i al
t o t he prevent i on of product cont ami nat i on. %he overal l phi l osophy of our
management i s one of prevent i ve 0ual i t y Assurance rat her t han ret rospect i ve
0ual i t y (ont rol .
Management has made available sufficient budget and resource to fully implement staff training
and education programmes. %he continual updating and improvement of hygiene standards is
our management goal.
GMP in 'tores:
i. (o ra) *ateria+ or pac,in% *ateria+ +ies in the stores )ithout "ein% chec,ed
"y the -ua+ity Contro+ Dept.
ii. .he stoc,s +yin% in the stores are rotated.
iii. ++ the *ateria+ is ,ept on p+at'or*s a"out 4 to 5 inches a"o$e %round and
a)ay 'ro* side )a++s.
Prepared "y #ssued "y ppro$ed "y Pa%e / o' 6


Unipex Dairy Products Co. Ltd.;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
i$. Sea+ed containers )hich are opened 'or -ua+ity Contro+ inspection, as 'ar as
possi"+e are i**ediate+y issued to production 'or use and not ,ept open 'or
+on% ti*e.
$. .he stoc,s are ordered as per re0uire*ent. -uantity ordered depends on she+'
+i'e, *ini*u* econo*ica+ 0uantity 'or transport and consu*ption, so that
stoc,s do not %et spoi+ed or da*a%ed.
$i. 1a) *ateria+s are recei$ed as per speci'ications.
$ii. (o insecticides or pesticides are stored in the area )here 'ood *ateria+ is
stored.
$iii. Pest contro+ is done *onth+y.
ix. ++ the ite*s are proper+y +a"e+ed at a++ ti*es in the stores.
x. La"e+in% 2 sta*pin% o' inner "oxes 'a*i+y pac,s, outer cartons etc. 'or
production use are proper+y done )ith respect to production 2 expiry dates,
code nu*"er and $ariety na*e.
xi. !ach and e$ery ite* is separate+y stored and there is no *ixin% up o' the
ite*s in the stores.
xii. 1ejected %oods are returned "y the stores as 'ar as possi"+e i**ediate+y and i'
they are ,ept in the stores 'or a short period, they are +a"e+ed as 31!4!C.!D5
and 'o++o) up is done 'or returnin% the sa*e to the supp+iers under proper
docu*entation.
GMP in Mix Room:
i. ++ the dry in%redients especia++y sta"i+i6ers and e*u+si'iers )hich are added
in s*a++ 0uantities are )ei%hed accurate+y and *ixed thorou%h+y to a$oid
+u*pin% o' the %u*s.
ii. 1a) *ateria+s to "e used are tasted or%ano+eptica++y and ensured it is 'it 'or
production "e'ore use.
iii. .he *ix is pasteuri6ed at 7/8C 'or /5 seconds in 9.S..
Care is ta,en that the pasteuri6ed *ix is not he+d at this te*perature in any
case *ore than / hours, other)ise the $iscosity o' the *ix increases and it is
di''icu+t 'or the pu*p to pu++ the *ix and pass throu%h p+ate chi++er.
i$. .he *ix is ho*o%eni6ed at &7::;/::: and 4::;5:: psi at &
st
< /
nd
sta%e
respecti$e+y, )hi+e *ix is at 65 to =:C. >or $iscous *ixes pressure ran%es
'ro* &5:: to /::: psi.
Prepared "y #ssued "y ppro$ed "y Pa%e ? o' 6


Unipex Dairy Products Co. Ltd.;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
$. .he on +ine 'i+ters in "et)een are opened and )ashed as o'ten as possi"+e to
re*o$e the so+id partic+es o' S.@.P or %u*s or any other so+ids deposited on
the 'i+ter.
$i. .his *ix is coo+ed to 4 to =C throu%h the p+ate chi++er "e'ore "ein%
trans'erred to a%ein% $ats. So*e $iscous *ixes di''icu+t to pass at =8C, in this
case te*p )i++ "e "e+o) &58C and consu*e *ix )ithin /: hrs.
$ii. @ix is pre'era"+y a%ed 'or *in / hours "e'ore it is ta,en 'or 'ree6in%.
$iii. .he $ats are e*pty and thorou%h+y c+eaned "e'ore passin% 'resh *ix into it.
ix. @ixes )hich are a%ed 'or *ore than 47 hours, are retested 'or acidity, and i'
re0uired can "e reprocessed "e'ore use.
x. .he te*perature o' *ix in a%ein% $at is *onitored throu%h the insta++ed Ca+
Contro+ .e*p. recordin% syste*. #n case o' 'ai+ure te*p. shou+d "e *anua++y
recorded in the *ix re%ister.
xi. Batch nu*"er and type o' *ix and date can "e put on the $at i' re0uired to
a$oid %ross *isuse o' *ix.
GMP in Production:
i. @ixes co+ored and '+a$ored, ready 'or 'ree6in% are tasted 'or '+a$or and co+or
or%ano+eptica++y.
ii. .he 'ro6en product co*in% 'ro* 'ree6er is chec,ed 'or te*perature o' 'ree6in% A;
4 to ; 6CB, "ody and texture.
iii. .he 0uantity o' secondary in%redients %oin% into the product is chec,ed 'or its
con'or*ity )ith standard 'or*u+ations.
i$. Pac,s o' #ce Crea* are coded 'or the "atch nu*"er and production code nu*"er,
so that it is easy to trace 2 +ocate the product in case o' product reca++.
$. !xcess unused pac,in% *ateria+ o' the day +yin% in the production ha++ is returned
to the stores under proper docu*entation or ,ept at desi%nated p+ace.
$i. .he +e't o$er excess opened cartons o' ra) *ateria+ 2 pac,in% *ateria+ are
proper+y co$ered to a$oid insect in'estation and ,ept in order unti+ they are
consu*ed.
$ii. La"e+s o' '+a$our "ott+es are retained unti+ the product is consu*ed and the "ott+es
are ti%ht+y capped as the essence are $o+ati+e and the stren%th o' the '+a$or *ay
decrease and a+so conta*ination *ay ta,e p+ace. >#>O is o"ser$ed strict+y.
$iii. Durin% inter$a+s o' production, containers o' secondary in%redients "ein% added
to are co$ered )ith +ids to a$oid 'orei%n *ateria+ conta*inatin% the product.
Prepared "y #ssued "y ppro$ed "y Pa%e 4 o' 6


Unipex Dairy Products Co. Ltd.;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
ix. .he ca+ciu* ch+oride A"rine so+utionB so+ution is chec,ed 'or speci'ic %ra$ity and
p9. Speci'ic %ra$ity shou+d "e &./7. 9i%her the concentration *ore is the 'ree6in%
capacity.
x. Durin% the chan%e o$er o' product in case o' "ars and candies, the *ou+ds are
thorou%h+y c+eaned and no *ix o' pre$ious production is +e't o$er in the *ou+ds.
+so nuts "o+ts and spi,es are ti%ht enou%h not to 'a++ into the product.
xi. ++ *eta+ detectors are )or,in% and $eri'ied 'or its 'unctionin%.
xii. (o %+ass apparatus +i,e *easurin% cy+inders or jars are used in productions.
xiii. O$errun or )ei%ht per piece o' the product is chec,ed on +ine as per standard.
xi$. Under;'i++in% or o$er;'i++in% o' products shou+d not do.
x$. Secondary in%redients are tasted "e'ore use. Care is ta,en )hi+e addin% to 'ruit
'eeder to a$oid any conta*ination )hi+e hand+in%.
x$i. 1e)or, i' any is added to *ix "+ender in appropriate *ix "atches "e'ore
pasteuri6ation in *ix roo* and detai+s recorded on *ix process contro+
sheet.
GMP in Despatch and Cold Room Section:
i. .e*peratures o' the co+d 1oo* are noted re%u+ar+y in the +o% "oo, 2 *onitor the
te*p. recordin% syste* is )or,in%.
ii. (o #ce Crea* is ,ept direct+y on the '+oor.
iii. #t is ensured #ce Crea* does not re*ain in the air+oc, roo* 'or unnecessari+y +on%
ti*e "e'ore it is "ein% trans'erred to the Co+d;1oo*.
i$. Care is ta,en )hi+e trans'errin% the pac,s, and are not hand+ed rou%h+y )hich
*ay resu+t in de'or*in% o' the pac,s.
$. #ce Crea* is issued to *ar,et on >#>O A>irst in >irst OutB "asis )ith the he+p o'
production 2 expiry and dates and production code.
$i. .he $ehic+es in )hich the ice crea* is transported to dea+ers 2 distri"utors are
thorou%h+y c+eaned.
$ii. #ce crea* is transported in re'ri%erated Cehic+es at ; &78C or "e+o) and te*p. is
recorded.
$iii. 1eturns or *e+ta%es recei$ed, chec,ed and disposed o''.
ix. #ce crea*s returned 'ro* the *ar,et in 'air+y %ood condition are not *ixed up
)ith the other stoc, in Co+d 1oo*, "ut ,ept iso+ated and are issued 'irst.
x. Loose #ce Crea* units are ,ept separate+y in one p+ace in the Co+d 1oo* and are
issued 'or 'ree sa*p+es and %uests and sta''.
xi. .he Co+d 1oo* and ir +oc, roo* doors are ,ept c+osed at ti*es.
Prepared "y #ssued "y ppro$ed "y Pa%e 5 o' 6


Unipex Dairy Products Co. Ltd.;
P.O. Box 5646 , Sharjah , U!.
Document : HACCP Manual Revision No. : 05
Title : Good Manufacturing Practices Date of ssue : 05!0"!#0"0
Shipping Guidelines:
&. !xport container #nspection is done and recorded in 'or*at pro$ided "e'ore
+oadin%. #n case o' non con'or*ance in'or* to La"oratory sta'' and ta,e
correcti$e action su%%ested and *aintain the record.
/. !nsure .e*perature o' container is achie$ed ; &78 C "e'ore +oadin%.
?. !nsure Co+d Store te*perature is "e+o) ;&78C "e'ore re*o$in% stoc,s to +oad.
4. Do not store pa++ets in ir +oc, *ore than &: *inutes.
5. rran%e a++ pa++ets in side the co+d store in %u++y pre'era"+y.
6. >u++ tracea"i+ity is recorded )hi+e shippin% and record shou+d "e easi+y a$ai+a"+e
'or *ini*u* &/ *onths.
=. One )or,*en )ho is ,ept 'or door openin% and c+osin% )ith co+d roo* dress
and he shou+d "e a+on% )ith o' the 'or,+i't to open and c+ose the doors o' co+d
stores as )hen needed and ensure that air is +oc,ed "et)een co+d stores and
outside. #' co+d roo* door is open then door o' air+oc, shou+d "e c+osed and $ice
$ersa. .his shou+d "e strict+y 'o++o)ed )ith dedication "y a++.
7. Doors o' containers )hi+e +oadin% shou+d "e c+osed i**ediate+y in "et)een the
+oadin% as needed ti++ )e *a,e co$ered +oadin% "ay.
D. !nsure that te*perature inside container is "e+o) ;&78C a'ter +oadin% and "e'ore
container is re+eased 'ro* the %ate and te*perature and other detai+s are recorded
as per 'or*at.
&:. Put t)o disposa"+e te*perature data +o%%ers in side the container "e'ore +ea$in%.
Prepared "y #ssued "y ppro$ed "y Pa%e 6 o' 6