Part A.1
|
PREMIUM CHEDDAR CHEESE
MASH
MIXING RECIPE & RECORD
|
DATE:
MIXER: EDEN OLD
|
INGREDIENTS
|
2
BIN
|
3 BIN
|
4
BIN
|
Notes:
|
POTATOES IN KG
|
420.0
|
630.0
|
840.0
|
(A) EMC WHT CHEDDAR
(Hansen Cheese ) Shelf life: 1 year frozen; 90 days
in cooler
(B)
PARMESAN CHEESE: PARM/ROMANO CHEESE (in label)
has a shelf life of 3 months
For both
ingredients, Date on ingredient label is Production Date
See more details in
INGREDIENTS LOT CODE INFORMATION binder
|
|
WATER
IN LITRES
|
30.00
|
45.00
|
60.00
|
|
EMC
(HANSEN) CHEDDAR CHEESE IN KG (A)
|
14.10
|
21.15
|
28.20
|
|
PARMESAN
CHEESE (B)
|
6.00
|
9.00
|
12.00
|
|
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 Parmesan
Cheese, Hansen cheese and prepared spices for this flavour
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
|
Part
A.2
|
PREMIUM CHEDDAR CHEESE
INSTRUCTIONS
|
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