Part A.1
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GENERIC
CHEDDAR PEROGY
MASH MIXING RECIPE & RECORD
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DATE:
MIXER: EDEN OLD
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INGREDIENTS
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2 BIN
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3 BIN
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4 BIN
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Notes:
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POTATOES IN KG
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420.0
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630.0
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840.0
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(1)
Annatto B/B
date: add 6 months to Production date
ITEM: 70451
Label: CHEESE
COLOR SINGLE STRENGTH
See more details in INGREDIENTS LOT CODE
INFORMATION binder
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WATER IN
LITRES
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30.0
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45.00
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60.00
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ANNATTO
(1) IN GRAMS
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371
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556
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742
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STOP MIXER WHEN
ADDING INGREDIENTS; BOMBA IS RAISED, USING A SCRAPER, OR TAKING SAMPLES
(1) MIX BY TIME is recorded on the
MASHLINE CONTROL SHEET and is the time of the EARLIEST bins used for the mix
Add 2 bins of mash. (For 2 bin mix, add 1 bin first). All bins
with mash must remain lidded when going from mash area to mixing rooms lids
to be removed just prior to each bin being lifted on the elevator
Do not use plain mash if the
MIX BY TIME has expired
Add water as per above chart for the mix size being
made
Add Annatto (Cheese Color Single Strength).
When adding ingredients,
document the LOT # BEFORE adding
the next ingredient
At every ingredient lot code
change, the new lot codes must be recorded (and the weight for each) in a
separate column. When a new lot code
is used, a second trained personnel must conduct on-site verification and initial
alongside new lot code number recorded by first employee
After
opening the inside plastic bag, ingredients are inspected for integrity (ie,
absence of signs of damage, foreign objects and/or contamination) before use. Record on INGR.
INTEGRITY CHECK column
Mix for 5 minutes and add
the remaining bins of mash and mix for another 5 minutes
FOR ALL MIXES, dump two bins
of filling and return them to the mixer to clear un-mixed plain mash from
around the door
Dump the contents into clean
Graco drums AFTER taste tests are completed.
Properly cover and label
each drum WITH FLAVOUR; LINE TO BE USED ON AND EXPIRY TIME
(6) Record the time the last drum of a mix was
completed on the line
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Part A.2
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GENERIC CHEDDAR PEROGY
INSTRUCTIONS
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Person Responsible: Mixing staff and Lead Hand or designate
Instructions:
(5) Record the
time the mix is verified for texture and put on Graco pump
IF MASH TEXTURE AT THE END OF MASH
COOLING CONVEYOR DOES NOT ALLOW FOR WATER ADDITION, PRODUCTION MANAGER MUST
CREATE INCIDENT REPORT
(2) TASTE TESTING INSTRUCTIONS:
Each mix is to be taste tested WHILE STILL IN
THE MIXER BY TWO APPROVED TASTE TESTERS before DUMPING into a Graco drum,
For the taste test instructions see FILLING TASTE
TEST-SOP.
Assigned persons must
circle S or NS and print their initials in the Taste Test Column indicating
that mixes have been taste tested. If at least one of the tasters circled NS
follow the Deviation Procedure below
Deviations:
In a case that at least one of the tasters marked
the filling as NS, the Production Manager to be informed immediately and
create an Incident report. The Food Safety Team will decide if the filling will
be used.
If the FST is not available use the filling and put
the product on hold.
Filling that has reached the FOUR hour limit, but LESS than 4 hours, can go on the Graco pump
with the following considerations:
Before the 4 hour limit, filling needs to be taste tested
by at least one FST member and needs to be found satisfactory
Taste test results by FST must be recorded before
filling is used. Record in Comments
Breaks should be taken after that drum has been
completed if close to expiry time to avoid waste
If breakdown occurs, throw out any filling ahead of
time if breakdown will put mash past expiry time
and document on an Inventory Adjustment Sheet. This will save time at a re-start
(3) Mixer Rinsing:
Mixer is to be thoroughly rinsed every FOUR HOURS (4 hours), plus THIRTY minutes, during production
from the LAST TIME MIXER WAS PUT BACK INTO USE (4)
As Graco drums are emptied they need to be thoroughly rinsed before the
next mix
Before rinsing ensure all mixing ingredients are removed from the mixing
room
Reefer fans must be turned off before rinsing the mixer
Rinse off all food material from the interior of the mixer, and door
assembly with a low-pressure hose
Use the perforated drum to catch solid waste from the mixer to prevent
solid waste being washed down the drain
Clean the mixer paddle or scraper as well
Rinse all areas until surface is visibly clean and spray 200 ppm Ster-Bac
to sanitize
After thoroughly rinsing the mixer, wipe
the condensation on the ceiling and fan before preparing the next mix
If any time
condensation is observed forming (other than after mixer is cleaned), remove
products from the mixing room and inform Production Manager or designate for
further instructions
P2 or trained designate is to
check and record that rinsing has been done properly as per instruction to
prevent contamination and also to ensure the wipe down of the walls and
ceilings to prevent buildup of condensation has been done. This check is to be done by a person different than the
one who rinsed the mixer.
Check is recorded on MIXER
CHECK AT BY
Part
B.1
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GENERIC CHEDDAR PEROGY
SPICE LOT CODE TRACKING
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DATE:
LINE: CDN
USA
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MIX NUMBER
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CDN #
USA #
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CDN #
USA #
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CDN #
USA #
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CDN #
USA #
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CDN #
USA #
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2 3
4
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2 3
4
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2 3
4
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2 3
4
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2 3
4
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TUB
# 1 (for 4 bin only 2 and 3 bin in one tub)
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SALT - KG
LOT
#
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4.94 7.41
9.88
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4.94 7.41
9.88
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4.94 7.41
9.88
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4.94 7.41
9.88
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4.94 7.41
9.88
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INGR. INTEGRITY
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BEST BEFORE DATE:
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WHITE PEPPER - KG
LOT #
ITEM: # 3-2060-LB
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0.28 0.41
0.55
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0.28 0.41
0.55
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0.28 0.41 0.55
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0.28 0.41
0.55
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0.28 0.41
0.55
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INGR. INTEGRITY
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BEST BEFORE DATE:
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ONION POWDER - KG
LOT #
ITEM: # DUS558C-LBBX
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1.53 2.29
3.05
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1.53 2.29
3.05
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1.53 2.29
3.05
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1.53 2.29
3.05
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1.53 2.29
3.05
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INGR. INTEGRITY
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BEST BEFORE DATE:
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TUB # 2 (for 4 bin only 2 and 3 bin in one tub)
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SUGAR - KG
LOT#:
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4.15 6.23
8.30
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4.15 6.23
8.30
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4.15 6.23
8.30
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4.15 6.23
8.30
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4.15 6.23
8.30
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INGR. INTEGRITY
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BEST BEFORE DATE:
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CHEESE SEAS (KERRY) - KG
LOT #
ITEM # 626948
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2.15 3.22
4.29
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2.15 3.22
4.29
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2.15 3.22
4.29
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2.15 3.22
4.29
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2.15 3.22
4.29
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INGR. INTEGRITY
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BEST BEFORE DATE:
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SPICE MIX WEIGHT (record actual weight on
each tub as per Spice Preparation SOP. Record added value and compare with
theoretical value on back page.
Allowable variance:
10 g
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COMPLETED
BY:
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Part
B.2
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GENERIC CHEDDAR PEROGY
SPICE RECIPE
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INGREDIENTS in KG
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2 BIN
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3 BIN
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4 BIN
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SALT
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4.94
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7.41
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9.88
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WHITE PEPPER
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0.28
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0.41
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0.55
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ONION POWDER
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1.53
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2.29
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3.05
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SUGAR
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4.15
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6.23
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8.30
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CHEESE SEAS 626948 (KERRY)
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2.15
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3.22
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4.29
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TOTAL SPICE WEIGHT
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13.05
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19.56
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26.07
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INSTRUCTIONS
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Person
Responsible: The Spice
Mix Person.
This Recipe and Record Sheet MUST be present at
all times
RECORD LOT # S AND BEST BEFORE CODES ON THIS
SHEET AFTER THE INGREDIENTS ARE ADDED TO THE MIX, THIS IS TO ENSURE THAT ALL
INGREDIENTS ARE ADDED TO THE MIX.
Do not PRE-FILL out ANY information on this sheet
The use of DITTO marks across columns for the
same weights and Lot # is NOT allowed.
There should be NO blank areas for any completed
mixes
At every ingredient lot code change, the new lot
codes must be recorded (and the weight for each) in a separate column. When a new lot code is used, a second
trained personnel must conduct on-site verification and initialize alongside
new lot code number recorded by first employee
When opening ingredient bags with more than one
lining, ALWAYS pull away outer bag layer BEFORE cutting top of inner layer to
prevent contamination from shipping and
storage to get into ingredient
After opening the inside
plastic bag, ingredients are inspected for integrity (ie, absence of signs of
damage, foreign objects and/or contamination) before use. Record on INGR. INTEGRITY
After opening the inside
plastic bag, ingredients are inspected for integrity (ie, absence of signs of
damage, foreign objects and/or contamination) before use. Record on INGR. INTEGRITY
Label mix numbers in sequence CDN # 1, CDN # 2,
CDN # 3, CDN # 20 etc for CDN line and
USA # 1,
USA # 2, USA # 3 .USA # 12 etc for USA line.
Do not make copies of this form - sheets must be
signed originals from the office
Cover the spice mix container with a plastic lid
when mix is complete
Clearly label each container with the Date;
Recipe Name; Mix Size, Mix Number and Line to be run on
Example:
APR 25 2017
GEN CHED
4 BIN MIX # 5 CDN
1 OF
2
APR 25 2017
GEN CHED
4 BIN MIX # 5 CDN
2 OF 2
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