Arman - Master Control Document - Draft

Table of Contents
TABLE OF CONTENTS
Chapter No. Title Page No.
1. Product Description
2. Recipe
3. RM Specifications
4. Material Movements
5. Process flow & Process Mapping
6. PM Specs (Verification & Movements)
7. Storage
8. FG Specifications
9. Dispatch & Transportation
10. NPD trials & lists
11. Document Lists
12. SOPs
13. Master cleaning & sanitation schedule

Chapter 1 Product Description
PRODUCT DESCRIPTION
1. Product name : Whole wheat chapati

2. Ingredients : Whole Wheat Flour (Atta), Sunflower oil, RO
Purified water, Iodised Salt, Sugar and natural improver, Sunflower
oil
3. Product Size : 8.5±3 inches
4. Consumption : Ready to Cook
5. Product weight : Min. 50g
6. Pack weight : 625g
7. Shelf Life : P+6 Days
8. Transport & Storage : <5°C
9. Appearance and Consistency : Creamish
brown in color, Flat and round in shape
10. Nutritional information per 100g product (Approx):
i. Energy : 273.96 kcal
ii. Protein : 11.89 g
iii. Carbohydrates : 48.09 g
iv. Saturated Fat : 0.46 g
v. MUFA : 1.36 g
vi. PUFA : 1.96 g
vii. Sugar : 0g
1
Chapter 2 Product Description
viii. Cholesterol : 0 mg
ix. Sodium : 1402.05 mg
x. Dietary Fiber : 7.37 g
11. Allergen : Contains wheat gluten
12. Intended use : All age groups
13. Consumption : Ready to Cook
14. Directions for Use:
a. Method 1: Heat each Chapati on a flat pan for 30 to
40 seconds on both sides or until the Chapati fluffs
up.
b. Method 2: Preheat oven to 95 ˚C / 200˚ F. spray
cooking oil on the griddle and cook each Chapati on
medium heat for 5 seconds a side or until the Chapati
fluffs up
Chapter 2 Recipe
1. CHAPATHI – RECIPE DETAILS
Ingredients Quantity
Wheat atta (Vivek Agro) 25 kg
Wheat atta (Annapurna) 25 kg
Oil 3.75 g
Salt 0.7 g
Sugar 0.3 kg
Improver 35 g
Water 33.5 litres
Total Wt (approx.) kg 88.55 Kg
1. Wet dough ball weight : 53-55grams
2. Top Plate Temperature : 180 degree celsius
3. Bottom Plate Temperature : 170 degree Celsius
4. Pressure : 4 bar
5. Cooling time : 1.5-2 min
6. After cooking chapati weight : 50-52 grams

Chapter 3 RM Specifications
1. ATTA SPECIFICATIONS
General Description:
Atta refers to the coarse product obtained by milling or grinding clean wheat free from rodent hair and
excreta. It shall be manufactured according to Good Manufacturing Practices and be compliant to a
suitable and sufficient HACCP system. It shall be free from foreign bodies and not be adulterated or
misbranded.
Biological, Chemicals and Physical Characteristics:
Moisture content : 10-13% by weight (when determined by heating

at 130°C- 133°C for 2 hours)
Total Ash : NMT 2.0% on dry weight basis
Acid Insoluble ash (on dry basis)% by mass : NMT 0.15% on dry weight basis
Gluten (on dry basis)% by mass : 8-9.5%
Gluten (on wet basis)% by mass : 28-30%
Water absorption : 64-68%
Alcoholic acidity (with 90% alcohol) expressed as H2SO4 (on dry basis): Not more than 0.15%
Granularity : Zero % retention on mesh BSS#60, 95%

retention on mesh BSS #200
Yield per kg : 20 pieces
Metal contaminants : As per FSSAI requirement
Crop contaminants : As per FSSAI requirement
Pesticide residues: As per FSSAI requirement

Composition and Origin:

Composition : Atta
Appearance and Consistency : Dark Creamish flour

Source : Plant origin
Country of Origin : India
Microbiological Parameters
Aerobic plate count : 100000
Enterobacteriaceae(Coliform) : Absent in 25 gm
E.coli : Absent in 25 gm
Yeast &Moulds : 500
Salmonella : Absent in 25 gm
Organoleptic parameters- FG
Colour & Appearance : Brown coloured, layered parota
Aroma : Fresh wheat flour aroma, Free from musty rancid flavour
: Atta flavoured, salty noted in aftertaste. With good

Taste/Mouthfeel lingering effect of atta flavoured layers.
Packing and storage Information

Packaging and content : Packed in a clean Oven bag with inner
polythene layer.
Shelf life : 4 months
Storage condition : Ambient condition
RM condition : Free from any insect live or dead.
Transportation Condition : Materials are transported in hygienic condition,
so that cross contamination and damages can be
avoided.
Disclaimer
This Raw material specification describes the composition and properties of our Raw materials to the
best of our knowledge. This raw materials complies with FSSAI and HALAL standards.
2. SALT SPECIFICATIONS
Iodized salt means a crystalline salt white or pale pink or light grey in colour, free from
contamination with clay grit and other extraneous adulterants.
It shall be manufactured according to Good Manufacturing Practices and be compliant to a suitable
and sufficient HACCP system. It shall be free from foreign bodies and not be adulterated or
misbranded.

Moisture content : NMT 6.0% by weight
Sodium chloride (NaCl) : Not less than 96.0% by weight on dry basis
Matter insoluble in water : NMT 1.0% by weight on dry basis

Matter soluble in water other than NaCl : NMT 3.0% by weight on dry basis
Iodine content at:

1. Manufacture level: Not less than 30.0 ppm on dry weight basis
2. Distribution channel including retail level: Not less than 15.0 ppm on dry
weight basis
3. Pesticide Residue: Nil

Composition : The product may contain food additive permitted in these regulations including
Appendix A. The total matter insoluble in water where an anticaking agent has
been added shall not exceed 2.2% and NaCl content on dry weight basis and
shall not be less than 97.0% by weight.
Appearance and Consistency : White colour, free flowing powder

Odour : Characteristic odour
Flavour : Characteristic flavour


Packaging and content : Packed in a clean polythene bag/pack.
Transportation Condition : Materials are transported in hygienic condition,so that the cross
contamination and damage can be avoided
Disclaimer
best of our knowledge. This raw materials complies with FSSAI and HALAL standards.
3. SUGAR SPECIFICATIONS
Refined Sugar means the white crystallized sugar obtained by refining of plantation white sugar. It
shall be free from dirt, filth, iron filings and added colouring matter. Extraneous matter shall not exceed
0.1 per cent by weight.
It shall be manufactured according to Good Manufacturing Practices and be compliant to a suitable and
sufficient HACCP system. It shall be free from foreign bodies and not be adulterated or misbranded.
Sucrose : Not less than 99.5% by weight on dry basis

Composition : The product may contain food additive permitted in these regulations
including Appendix A.
Appearance and Consistency : White colour, Crystalline structure

Odour : Characteristic odour
Flavour : Characteristic flavour


Packaging and content : Packed in a clean polythene bag/pack.
Transportation Condition : Materials are transported in hygienic condition, so that the cross
contamination and damage can be avoided
Disclaimer
best of our knowledge. This raw materials complies with FSSAI standards.
4. SUNFLOWER OIL SPECIFICATIONS
Sunflower seed oil means the oil obtained from clean and sound sunflower seeds or cake from the
plants Helianthus annus Linn (Family: Compositae) by the method of expression or solvent
extraction. It shall be clear, free from rancidity, suspended or other foreign matter, separated water,
added coloring or flavoring substances or mineral oil.

Free fatty acid : NMT 0.25%
Refractive Index at 40°C : 1.4640- 1.4800
Butyro-refractometer reading at 40°C : 57.1-65
Flash point (pensky marten closed method): NLT 250°C
Iodine value (Wij’s method) : 100-140
Saponification value : 188- 195
Peroxide value : NMT 10 mEq/kg
Unsaponifiable matter % by weight
For chemically refined : NMT 0.5%
For physically refined : Negative
Oryzanol content : NLT 1% by mass
Hexane : NMT 5.00 ppm
Clarity Test:
The Refined Sunflower Oil shall not show any turbidity after keeping the filtered sample at 300 C for
24 hours.
Composition : Rice bran oil
Appearance and Consistency : Dark golden liquid
Source : Plant origin

Odour : Characteristic, free from foreign odour
Flavour : Characteristic, free from foreign flavour

Packaging and content : Packed in cans
Transportation Condition : Materials are transported in hygienic condition, so that cross

contamination and damages can be avoided
Disclaimer
best of our knowledge. This raw material complies with FSSAI and HALAL standards.
RM testing & verification

General Verification while receiving RMs
• Raw material should be procured from approved vendors only.

• The material should comply with the RM specification.
• Cross-check COA received with the provided Standard Specification.
• Check the Date of Manufacture and the expiry to match with the COA provided by the Vendor.
• Check the temperature, packaging condition and necessary inspection of the product or raw
materials as per the product specification sheet before unloading the product.
• Inspect truck for, unacceptable odour, cleanliness, condition of trailer, evidence of pests.
• The transportation of goods should pose no cross-contamination risk.
• The Raw materials should be carried to its respective storage areas for storage.
• If any threats are found in the RM after receiving, the entire batch should be isolated and stored in
the rejection area. The vendor should be notified immediately for replacement
Atta
• Take around 100g of samples from 3 different random sacks each.
• Spread up the Atta over a white sheet of paper and check for any foreign
General matter or black particle.
• Check for lump accumulation
• Check for any infestation
• Take 10g of Atta and dissolve in 100 ml of RO water
Solubility • Stir the solution with a stirrer.
• There should not be any lump formation or any foreign matter.
• Take 25g of Atta
• Then slowly add water and mix it with the flour until the dough becomes soft
and non-sticky.
Water Absorption
• Note down the amount of water added and measure up the water absorption
percent using the formula
• (Amount of water used/ Weight of sample)*100
• Take 25g of Atta
• Then slowly add water and mix it with the flour until the dough becomes soft
and non-sticky.
• Soak it in water for 1 hr
• Wash the dough properly until all the starches are removed
Wet Gluten
• Replace the bowl's water frequently and ensure all the starchy particle left is
removed.
• Squeeze out the excess water and calculate the wet gluten percentage using
the following formula,
• (weight of gluten after washing/weight of dough)*100
Sugar
• Weigh 5g of water in a beaker
• Dissolve it in a 100ml of water with a spatula
Solubility
• The sugar should be completely dissolved and there should not be any
foreign particle or black particles
Salt
Weigh 5g of water in a beaker
Solubility Dissolve it in a 100ml of water with a spatula
If the solution is transparent, then it passes the solubility test
Chapter 4 Material Movements
Material Movements
RM Receival:
• Raw material should be procured from approved vendors only.
• The material should comply with the RM specification.
• Cross-check COA received with the provided Standard Specification.
• Check the Date of Manufacture and the expiry to match with the COA provided by the
Vendor.
• Check the temperature, packaging condition, and necessary inspection of the product or
raw materials as per the product specification sheet before unloading the product.
• Inspect truck for, unacceptable odour, cleanliness, condition of trailer, and evidence of
pests.
• The Raw materials should be carried to their respective storage areas for storage, and it
should be arranged in a way that it can be accessible for further verification.
• Once Raw material has been received, the sample from the received lot must be
immediately sent to the iD Anekal plant for chemical & microbial analysis whichever is
possible. Along with that, applicable in-house testing also should be done.
• The material should be on hold, and it should not be used for production until the
material is found to be in match the standard specification.
• If any threats are found in the RM after receiving, the entire batch should be isolated
and stored in the rejection area. The vendor should be notified immediately for a replacement.
PM Receival:
• Packing Material should be procured from approved vendors only.
• The material should comply with the PM specification.
• COA of the PM should be collected and verified.
• Check the Date of Manufacture to match with the COA provided by the Vendor.
• Check for any damage or leakage of consignment
• Inspect truck for, unacceptable odour, cleanliness, condition of the trailer, and evidence
of pests.
• The Packaging materials should be carried to their respective storage areas for storage.
• Collect samples randomly from different consignments and perform dimension (Length,
Height, Gusset length, and thickness), odour, artwork verification, and leakage tests.
• Check and compare with the Approved shade cards for any deviation in packaging
material
• Check for any Foreign matters
• If the samples fail to pass the tests, the entire batch should be rejected and kept in the
rejection area. The vendor should be notified immediately for the replacement
15
Storage:
• Once RM has been approved and the material should be properly stored above the pallet
with proper labeling.
• There should be a minimum of 45cm gap between the wall & the RMs
RM Issuance:
• Whenever the Raw material is required for production, the request for the required
quantity has to be raised by the production manager and the same has to be issued by the
quality executive along with a proper record of RM issuance & sign-off from the store
manager/in charge.
• Then the Raw material should be issued and transferred to the production area through a
proper transporter/lift.
Mixing:
• Once the raw material has been shifted to the production area, materials must be
transferred to their respective storage bins with proper labeling.
• In the case of Atta, it has to be sieved properly through a shifter and transferred to the
SS containers with proper labeling.
• Once everything is settled, materials must be weighed properly according to the
approved batch size (50kg).
• Further mixing should be started after the proper verification of cleaning & sanitisation
of the mixer/bowl.
• The left-out RMs should be closed/sealed properly with proper labeling.
Dough Transfer:
• Once mixing ends, the dough has to be transferred to the well-cleaned and sanitized
table which should be available in the chapati-making area for proving.
• Dough transfer has to be done with proper wearing of clean and sanitised full-sleeve
gloves.
• Once Dough transfer is done, it should be completely covered with a plate/vessel.
Dough Dividing & Chapathi making:
• Once proving is done, the required dough has to be divided and filled into the
compression vessel of the properly cleaned & sanitised Chapathi-making machine.
Sanitisation should be done including the conveyors, guides & plates.
• All the labours staffs, Executives & labours should be having proper head caps, gloves,
aprons, face masks, and beard masks.
• Further, Chapatis will be made & transferred through the conveyor to the plates marked
with the standard required chapati size.
• In the meantime, Chapatis should be checked for quality things like puffing, size, shape,
and hardness
Sorting & Packing:

• Chapatis should be properly sorted with respect to size, texture, and shape.
16
• After proper sorting, good & fine chapatis should be packed and sealed immediately &
arranged in a clean crate
• The PM should be properly printed with the coding as suggested which will be
consisting of price, date of expiry & Batch details.
FG to the cold room:
• Once the chapatis are properly sealed and packed with proper coding, the packets can
be checked for leakage tests by holding the whole packet within a vessel/bowl of water. Also,
the packets should be checked for proper visibility of coding
• Then the packets should be arranged in a crate according to approved stacking and
transferred immediately to the cold room
17
Chapter 5 Process flow & Mapping
Chapati production: process flow
* Receipt of PM - Delivery vehicle condition - checked.
- Documentation of product details.
- Stored on pallets in packaging material storage room
* Receipt of RM - Delivery vehicle condition - checked.
- Documentation of product details. COA to be verified
- Stored on pallets in raw material storage room.
- Ensure the RM are within the standard parameter range
* Sieving - Wheat flour to be sieved using sieving machine

prior to use.
*Mixing - RM to be weighed as per the recipe (Improver, Salt, Sugar to be

weighed with care)
-Above weighed RM to be mixed with Wheat , water and oil as per the
recipe
* Mixing time & -Mixing to be done for 25-30 minutes and gluten formation to be
Dough ball checked. Fermentation time 10-15 min
- Dough weight to be measured (53-55g) in dough divider
* Rolling & Pressing - Ball to be made using roller and placed in Dough Pressing (Top Plate
180 deg C and Bottom plate 170 deg C). Partially cooked Chapati (50-
51g)
18
* Dusting - Chapati formed will be dusted with Wheat atta flour to avoid
stickyness.
* Cooling - Chapati is passed in conveyor for cooling (1.5-2 min).
* Packing - Chapati has to be weight and packed in Packaging Material.
* printing/ - Label the packs with Useby date, MRP and batch code
Packaging and
Labeling - packing material.
- Check packaging box for correct MRP, Use by date, Batch numberand
product weight.
- Check the pack for sealing.
* Shelf life - Shelf life is 6 days in Chilled condition for Chapati
* Dispatch - Check product quality and product temperature. Check packaging

crates for cleanliness.
- Packaging and sealing quality.
- Product details.
- Vehicle condition.
- It should be clean and free from dust/pest infestation.
19
Process Mapping
Mixing:
• Mixing should be done with an approved/validated quantity (35 Kg)
• Mixing time should be 30±2 Mins.
• Atta, Sugar & Salt should be sieved properly before using.
• Ingredients should be properly weighed to the required quantity.
• Atta has to be properly weighed to the required quantity. Following, the required
amount of improver should be weighed and mixed along with Atta.
• Water has to be added in the four parts in the following quantity according to the
current recipe – 7.6/7.6/7.5/0.75 Kg. Oil has to be added in four parts as -
750g/750g/750g/375g
• The required quantity of Salt & Sugar has to be dissolved in the first part of the Water
• Then the water mixer should be poured into the Dough mixer, then Atta has to be
added.
• Afterward, Mixing should be started at a slow speed @ 25 RPM and the first part of oil
should be added slowly to the mixing flour.
• For every three minutes, there should be a change of clockwise and anticlockwise
rotation of the spiral hook throughout the mixing.
• After 5 mins of mixing, the second part of water should be added, and the next part of
oil should be added slowly.
• After 10 mins of mixing, the third part of water should be added, and the next part of oil
should be added slowly.
• After 18 mins, fast mixing should be done for 2 mins.
• After 20 mins of mixing, the final left-out quantity of water should be added slowly to
the dough.
• Finally, the dough should be transferred to the proving table in a safe & hygienic
manner.
• Documentation of actual ingredients used during mixing should be done in the form of
an approved Batch sheet.
(Ref. checklist: AR/CHK/001)
Proving:
• Once mixing ends, the dough has to be transferred to the particular proving table which
should be available in the chapati-making area.
• The proving time should be in the range of 10-15 Mins.
• The Dough should be completely covered with a plate/vessel.
• The actual time taken for proving should be documented
Dough Dividing & Chapathi making:
20
• Chapathi making machine should be pre-setted to the required temperature and

pressure.
• The pressure of the compression plates should be at 3.5 bar and the temperature of the
plates should be at 180°C & 170°C for the Top & Bottom, respectively.
• The maximum temperature variation of the plates should be always ± 20°C. If the
temperature is found more/less, chapati making should be immediately stopped and it can be
continued once the required temperature has been acquired.
• Once proving is done, the required dough has to be divided and kneaded well as
suggested and filled into the compression cylinder in a proper manner (Dough should be
completely stuffed into the cylinder without any air spaces).
• Compression plates should be cleaned/wiped periodically (for 15-30 Mins).
• All the parameters (Temp, Time & Pressure) should be noted & documented.
• Chapati should be passed through the fan and the conveyors throughout the machine for
cooling. Chapathi should be weighed continuously before packing and the same should be
documented in the form of a checklist.
• Chapatis should be checked for any quality defects and changes should be done
immediately if needed.
• At the same time, a Minimum of 10-12 Chapathi should be cooked and checked for
proper puffing, colour, hardness, taste, and mouthfeel. A sensory score has to be given for all
the required checks and the same has to be documented in the sensory score checklist.
Sorting & Packing:

• Chapathi should be in the size range of diameter of 8.2-8.8 inches and thickness of 1-1.2
mm.
• Actual Chapathi sizes should be documented in the form of a checklist.
• The texture should be fine without any holes/damages all over the Chapathi
• All the chapatis should be minimum of 50g and the packet weight should be 600g.
• So, Chapatis should be properly sorted with respect to size, weight, thickness, texture,
shape, and breakage.
• If any deviations are found, it should be immediately informed to the operator for
necessary changes/alterations in the machine
• Chapati should be packed ASAP without any breakage/folding along with all other
quality checks.
• After proper sorting, packets should be sealed immediately & weighed, and the same
has to be documented.
• Once Chapatis are completely packed, the packets should be verified for their sealing
condition, printed data legibility, MRP, leakage, and crate condition. The same has to be
documented
(Ref. checklist: AR/CHK/004) & (Ref. checklist: AR/CHK/011)
21
• Finally, it should be kept in clean crates and immediately transferred to the cold room.
Printing of PM:
• PMs should be printed with MRP, Expiry, and Batch details.
• The Batch details should be in the following format,
o AH (DATE) B (BATCH NO) A(B)
▪ A - Arman
▪ H - Respective month in their Alphabetical No.
▪ DATE - respective production date
▪ B - Batch
▪ BATCH NO - Respective batch no.
▪ A/B - Respective Shift
• The printing should be accurate and possess proper visibility for every packet.
FG & Cold storage:

• Once the chapatis are properly sealed and packed with proper coding, they should be
properly arranged as per approved stacking & immediately transferred to the cold room
ASAP.
• The packets can be checked for leakage tests by holding the whole packet within a
vessel/bowl of water.
22
Chapter 6 PM specs (Verification & Movements)
Whole Wheat Chapati Artwork
23
PM Specifications
GENERAL INFORMATION
Document No ID/PM/Spec
Product Name Chapati
Market India
Created Date 23/05/2022
Revision No 01
Revision Date 13/06/2022
PACK DETAIL
Item Code PM 015
Pack Type Centre seal preformed pouch without zipper
Material 12mic CTDPET/ 60mic (Tr) LDPE
Structure
Process Printing-Lamination-slitting-Pouching
Decoration
Print Method Gravure Print (Reversed Print)
DETAILED SPECIFICATIONS
GENERAL AND VISUAL TEST
Defect Defect Class
Any defect leading to failure in packaging line. Critical
Inappropriate size Critical
Poor machine performance Critical
Wrinkled pouches Major
24
Opening up of Pouch at sealing area Critical
Lesser quantity per box Minor
Unsealed Pouch Critical
Sealing at different place Critical
Stiffener at the base is not attached Critical
Presence of Pinholes Critical
Variation from approved artwork. Critical
Variation from approved shade card Critical
Different type of pouches in a pack, i.e., mixing up of

Critical
variant.
Dirt, dust or any foreign matter sticking to the pouch Critical
Visible at 50 cm
Major
distance-
Print defect like spot, ink smudge, Visible at 25 cm not at
Minor
wash print, mis-registration 50 cm distance-
Not visible at 25 cm
Acceptable
distance-
Visible at 50 cm
Major
distance-
Visible at 25 cm not at
Illustration, background and solid Minor
50 cm distance-
colour beyond standard
Not visible at 25 cm
Acceptable
distance-
25
FUNCTIONAL TEST
Test
Defect Supplier
Parameter UOM Standard Method/s Frequency
Class Certificate
standard
All
Pouch Height mm 275(+/-2) Manual Critical Yes
Supplies
All
Pouch Width mm 255(+/-2) Manual Critical Yes
Supplies
All
Seal Width mm 10(+/-2) Manual Critical Yes
Supplies
Total ASTM All

micron 72 (+/-1) Major Yes
Thickness F2251-13 Supplies
All
Total GSM g/m2 75(+/-5%) IS 1060 Major Yes
Supplies
All
Ink GSM g/m2 2 GSM max, Manual Major Yes
Supplies
Adhesive All
g/m2 2 GSM max Manual Major Yes
GSM Supplies
g/15m ASTM D All

Bond Strength Min 250 g/15mm Critical Yes
m 1876 Supplies
ASTM
F88
kg/15m All
Seal Strength Min3.5 Kg/15 mm – 68 Critical Yes
m Supplies
(1973)
(Part 21)
Proper quality ink shall be

selected as per IS 15495 and
shall be permissible under PFA
Rules All
Ink Grade Critical Yes
Food Grade Supplies
(Migration optimized
ink),Toluene Free Ink/ Toluene
based ink –as per requirement
26
High performance Solvent less

adhesives are to be used.
Lamination adhesives must be
Adhesive All
fully cured before dispatch. Critical Yes
Grade Supplies
There should not be any
tackiness/solvent retention in
laminate.
Heat
All
Resistance Should pass Major Yes
Supplies
Test
Light Fastness Should pass- Light fastness All

Major Yes
Test value: 6-7 on wools scale. Supplies
Shouldn't be any unwanted odour All

Odour Test Major Yes
in the laminate Supplies
OTR (23℃
and Cc/m2 ASTM D All
Critical Yes
0% RH)- 24H 3985 Supplies
(max)
WVTR (38℃
and G/m2- ASTM All
Critical Yes
90% RH)- 24H F1249 Supplies
(max)
Overall mg/dm
10 All
migration 2 IS - 9845 Critical Yes
Supplies
limit mg/kg 60
General Remarks / Notes: -
1) No solvent retention in laminates and free from any odour.

2) Pouches to be free from dust, foreign particles, air bubbles, scratches,
wrinkles, etc. While Printing layout of the laminate should be absolutely
Speckle free, Free from air bubbles, or any type of lamination defect. 3)
Printing should be sharp, clear and free from ink lines, ink spots, ink spreads,
smudging, print misregistration mottling, stretch mark etc. Print Color to
Critical match as per approved print proof.
Requirement: -
4) Easy tearabilty of filled pouch from the notch.
5) After filling of product and sealing of pouch at normal condition
product should never come out on pressing by hand in pressure.
6) No Delamination of printed / any layer of laminate should occur along

sealing area or on sealing after pouch is filled and sealed with product.
7) Shelf life of product of Min 1 years when stored in ordinary condition
27
8) GC (Gas chromatography) report is mandatory with laminate delivery.
1. The bags are to be packed properly and transported to

the factory in a clear, weather proof vehicle. The bags when received
at the factory are to be stored in a clean dry space free from dirt and
moisture hazards.
Packing
2. Pouches to be packed in a polyethylene cover inside
Instructions: -
the box to avoid any foreign body contamination.
3. Each consignment will be accompanied with a

packing list, quantity, quality report and test certificate
COA, GC report with sign and stamp should be presented before the
Shipping unloading process. Food grade certificate, Heavy metal migration and
documents: - Pthalate Content certificate should be submitted every 1 year which is
Mandatory.
28
Key Line Drawing: -
Approval by other Stake Signature Date

stakeholders Holders
Prepared By Pranay Singh
Functional Approval Shailendra
Final Approval Muralidhar
Brand Manager (Design & Deepika

KLD)
HOD Procurement Sandip
R & D / NPD Chandana
HOD Quality Sharmila
HOD - Manufacturing GLN Murthy
29
PM Verifications
• Collect samples randomly from different consignments and perform dimension (Length,
Height, Gusset length and thickness), odour, scrub test, artwork verification, sealing and
leakage tests.
• Check and compare with the Approved shade cards for any deviation in packaging
material
• Check for any Foreign matters
• If the samples fail to pass the tests, the entire batch should be rejected and kept in the
rejection area. The vendor should be notified immediately for a replacement.
Movement
• Whenever the production starts, the required quantity of approved PMs should be taken
in a closed manner taken to the production area and proceed for printing
30
Chapter 7 Storage
Storage of Chapatis
• Once the chapatis are properly sealed and packed with proper coding, they should be
properly arranged as per approved stacking in the crates & immediately transferred to the
cold room ASAP at the storage condition <5°C.
31
Chapter 8 FG Spec
FG Specifications
Information regarding composition:

Ingredients : Whole Wheat Flour (Atta), Sunflower oil, RO Purified water, Iodised Salt, Sugar
and natural improver
Allergen Information : Contains Wheat Gluten
Other information : Made Fresh with no Preservatives and Chemicals.
This product does not contain ingredients that contains GMO or consists of GMO or derived from GMO.
Information for application:

Appearance and Consistency : Creamish brown in color, Flat and round in shape
Consumption : Ready to Cook
Directions for Use : Method 1: Heat each Chapati on a flat pan for 30 to 40 seconds on both
sides or until the Chapati fluffs up.
Method 2: Preheat oven to 95 ˚C / 200˚ F. spray cooking oil on the
griddle and cook each Chapati on medium heat for 5 seconds a side
or until the Chapati fluffs up

Packaging and content : Aseptic Zip lock pouch in 500 g (10+2 no)
Shelf life in the unopened original packaging : At chiller temperature (50 c) Production + 6 days
Intended use: All age groups
Physical and Chemical Parameters:

Property Standards
Diameter : 8.5 ± 0.3 inch
Weight : 50 g
Moisture : 39±2 %
32
Chapter 8 FG Spec
Thickness : 1-1.2mm
pH (5% solution) : 6.0 to 6.4
Microbiology Parameters Standards Test Method

Total Plate Count : <1000 CFU/g AOAC Method
Coliform : <10 CFU/g AOAC Method
Salmonella : Absent /25g -
Yeast & Moulds : <10 CFU/g AOAC Method
E.coli : Absent /g -
Stapphylococcus aureus : <10 CFU/g AOAC Method
Nutritional Information
Nutritional information per 100g product (Approx)
Energy : 273.96 kcal

Protein : 11.89 g
Carbohydrates : 48.09 g
Saturated Fat : 0.46 g
MUFA : 1.36 g
PUFA : 1.96 g
Sugar : 0g
Cholesterol : 0 mg
Sodium : 1402.05 mg
Dietary Fiber : 7.37 g
Disclaimer
This Product specification describes the composition and properties of our products to the best of our
knowledge. Due to raw material variations, deviations from the specification may occur within good
manufacturing practice in order to standardize our product. This product and its ingredients complies with
FSSAI and HALAL standards.
33
TC-7970
TEST REPORT
ULR-TC797022000006024F
Report No : TUV(I)/219/22-23/9042210563
Date : 26 Apr 2022
Name & Address of Customer : ID Fresh Food(India)Pvt Ltd

TUV INDIA PRIVATE LIMITED #8, VK Commerce, 2nd Floor, lll Main
Road,6th Block, Opp. KSSIDC IT Park,
Rajajinagar,IndustrialEstate,
Bangalore - 560 010
Tel. : 080-40823000
Fax : 91-080-40823031
Email : blrlab@tuv-nord.com
515/2,515/3,515/4,516/2,516/3,516/4 & 533.
Madivala Village
Kasaba Hobli,Anekal Taluk.,
Bengaluru
Pi
n
C
o
d
e:
5
6
0
0
9
9
Reg No. : 219/22-23
CA No. : 9042210563
Date of sample receipt : 15 Apr 2022
Date(s) of analysis : 16 Apr 2022 - 26 Apr 2022
Sample Drawn by : Customer

LOQ/L
SlNo Test Name Results Unit Test Method
OD
Sample Name : Chapati CA No : 9042210563
Description: Brown coloured chapati Discpline: Chemical

Product Category; Food & Agricultural
Accredited Tests
Chemical Tests
1 Energy 273.96 Kcal/100 g -- By Calculation

2 Carbohydrate 48.09 g/100g -- TUVB/02/SOP/04
3 Dietary Fibre 7.37 g/100g -- AOAC (20th Edition) 985.29
4 Protein 11.89 g/100g -- IS 7219 :1985 (RA 2010)
5 Total Sugar Nil g/100g -- FSSAI Manual
6 Total Fat 3.78 g/100g -- FSSAI Manual
Instrument Lab
7 Cholesterol < LOQ mg/100g 0.5 TUVB/02/SOP/036
8 Sodium 1402.053 mg/100g - TUVB/02/SOP/35
Fatty Acid Profile

9 Saturated Fat 0.46 g/100g 0.05 TUVB/02/SOP/037 Based on AOAC
996.06 20th Edition
10 Monounsaturated Fatty Acid(MUFA) 1.36 g/100g 0.05 TUVB/02/SOP/037 Based on AOAC
996.06 20th Edition
11 Polyunsaturated Fatty Acid(PUFA) 1.96 g/100g 0.05 TUVB/02/SOP/037 Based on AOAC
996.06 20th Edition
12 Trans Fat < LOQ g/100g 0.05 TUVB/02/SOP/037 Based on AOAC
996.06 20th Edition
Page 35 of 155 Registered & Head Office : 801, Raheja Plaza-1, L.B.S. Marg, Ghatkopar (W), Mumbai - 400 086
Phone : (022) 6647 7000 • Fax : (022) 6647 7009 • e-mail : mumbai@tuv- nord.com • website : www.tuvindia.co.in
TUV NORD GROUP
TC-7970
TEST REPORT
ULR-TC797022000006024F
Report No : TUV(I)/219/22-23/9042210563
Date : 26 Apr 2022
LOD-Limit of Detection
LOQ-Limit of Quantification
Authorized by
Mr. Y.R. Sathishkumar

In charge – Wet Chemical
TUV NORD GROUP
TC-7970
TEST REPORT
ULR-TC797022000006024F
Report No : TUV(I)/219/22-23/9042210563
Date : 26 Apr 2022
Terms and Conditions
1. Test Results are based on & related only to the particular sample(s) tested.
2. This Report cannot be re-produced, except when in full, without the written permission from TUV India Pvt. Ltd.
3. This Certificate reflects our findings at the time and place of testing.
4. Sample(s) will be retained by us for a period of one month for non-perishable items only. Perishable items will be
destroyed after completion of tests.
5. This Report, in full or in part, shall not be used to make any misleading claims or for any legal purposes.
6. All terms and conditions of our quotation on the basis of which this testing service has been provided are deemed
to be fully accepted by the customer and are deemed to be in full force and effect.
7. This Report is exclusively for the use of the customer whose name and address is indicated above. No third party
can derive rights against the company on the basis of this report. No third party has any right to raise any claims on
the company.
8. For Biological and mycotoxin Analysis: Our analytical findings reflect the quality of the sample at the time of testing.
No responsibility can be accepted for the possible consequences of further development of micro-organisms or
mycotoxin which may depend upon storage, handling & weathers conditions which may influence the results at a
later date/time respectively.
9. The laboratory tests are conducted by TUV India as per mutual agreement without any implied warranty of
merchantability and fitness for any general or particular use. TUV India will not be liable for any claims for indirect,
incidental or consequential damages including but not limited to loss of revenue, loss of profits and similar claims.
TUV India will also not be liable under any strict liability, product liability or negligence. The total liability,
scientifically and legally proven, if any, of TUV India, in any case, shall not exceed the invoiced amount for the
services provided and paid for.
10. For Pesticide Residue analysis, reported value at LOQ level may vary within analytical variation of 50%
considering Uncertainty of Measurement.
-- End of Report --
TUV NORD GROUP
Chapter 9 Dispatch & transportation
Approved stacking of product in secondary packaging

Total approved stack of products in one crate (secondary packaging) : 20 Packets
No of crates that can be arranged in a row with easy accessibility : 10 Crates
Crate Dimension: Outer dimension of secondary packaging - crates (in cm) :L×B×H
: 50 × 32.2 × 20
38
Daily Dispatch Vehicle Inspection Details
Plant : Arman Foodtech Pvt. Ltd.

Product : Whole wheat Chapathi
Temperature : <5°C
Vehicle’s Details
Vehicle No : KA 52 B 3619
Chassis No. : MAT464660LSK08610
Engine No. : VARICOR12KZXJ08727
Crates Capacity/Trip : 141 approx.
No. of Chapathi/Trip : 2820 approx.
Max. Temp. reducible : -10°C
Attached Documents
• Vehicle inspection checklist
• Driver’s driving license
• Vehicle’s RC
• Vehicle’s insurance
• Vehicle’s pollution check certificate
• Vehicle’s goods permit
• Vehicle reference images
39
Vehicle Inspection Checklist

Audit Date: 16-08-2022
40
Driver’s Driving Licence
Vehicle’s RC
41
Vehicle’s Insurance
42
Vehicle’s Pollution Check Certificate
43
Vehicle’s Goods Permit
44
Vehicle reference images
45
Chapter 10 NPD trials & reports
NPD trials & reports
First Commercial Trial

Whole Wheat Chapathi
Arman Foodtech Pvt. Ltd.
25-07-2022
Recipe
Atta (kg) 25
(Vivek Agro &
Annapoorna) 25
Salt (g) 700
Sugar(g) 300
Improver(g) 40
Oil (ml) 3750
Water (L) 33.5
Mixing Started
01:25 PM
25kg of Vivek Agro & 25kg of Annapoorna Atta has been taken
11Kg of Water + Dissolved 700g Salt + Dissolved 300g of Sugar + Dissolved 40g of
Improver
Added 1350g of Oil
After 5 Mins
Added 11kg of Water
Added 1350g of Oil
After 5 Mins
Added 11.5kg of Water
Added 900g of Oil
Mixing Ends
01:48 PM
Proving Starts
01:50 PM
Dough has been transferred to the table and covered with trays for proving
It should be maximum of 10-15 Mins
Proving Ends
02:06 PM
Chapathi Making
02:07 PM
Pre-setting of Chapathi making machine was done
46
Compression pressure has been set at 5 bar

Compression plates temp has been set with Top 180C & Bottom 170C
Dough dividing level has been adjusted according to the requirement
The required amount of dough was filled into the compression cylinder
So the compression was started with the automatic dividing of dough. Then the dough was
verified for the required amount and adjusted accordingly.
After dividing, the dough was pressed/compressed with the required pressure &
temperature. The Chapathi will be passed through a fan attached to the conveyor for
cooling.
Finally Rice flour will be sprayed onto the chapthi which is kept on the attached siever.
This is to avoid the stickiness of chapathi with one another.
Chapathi Making Ends

05:30 PM
Printing
Once chapathi making started PMs will be printed for coding
Then, It will be given for Chapathi packing
Sealing of Packets
Once required no of chapatis were filled in the packs, and packets were heat sealed and
verified.
Process Observations & Deviations

The dough has been kept for proving more than the actual
Found more variations in dough dividing
Temperature of compression plates are not stable
Found variations in chapati size
47
Second Commercial Trial

09-08-2022
Recipe
Atta (kg) 7.5
(Vivek Agro &
Annapoorna) 7.5
Salt (g) 210
Sugar(g) 90
Improver(g) 12
Oil (g) 1125
Water (L) 10.05
Mixing Started
01:06 PM
7.5kg of Vivek Agro & 7.5kg of Annapoorna Atta has been taken + Mixed 40g of Improver
3.35Kg of Water + Dissolved 210g Salt + Dissolved 90g of Sugar
Added 375g of Oil
After 6 Mins
Added 375g of Oil
After 5 Mins
Added 375g of Oil
Mixing Ends
01:34 PM
(Additionally Mixed for 1 Minute)
Proving Starts
01:34 PM
It should be maximum 10 Mins
Proving Ends
01:54 PM
Chapathi Making
01:54 PM
Compression plates temp has been set with Top 180C & Bottom 170C
48
Required amount of dough was filled into the compression cylinder

So the compression was started with automatic dividing of dough. Then the dough was
verified for required amount and adjusted accordingly.
After dividing, the dough was pressed/compressed with the required pressure & temperature.
The Chapathi will be passed through a fan attached to the conveyor for cooling(1-2 Mins).
Finally Rice flour will be sprayed onto the chapthi which is kept on the attached siever. This
is to avoid the stickiness of chapathi with one another.

04:40 PM
Printing
Sealing of Packets
Once required no of Chapathis were filled in the packs, packets were heat sealed and verified.

(Repeated - First Commercial Trial )
Dough has been kept for proving more than the actual
Temperature of compression plates are not stable, Keeps fluctuating
49
Third Commercial Trial

13-08-2022
Recipe
Atta (kg) 17.5
(Vivek Agro &
Annapoorna) 17.5
Salt (g) 490
Sugar(g) 210
Improver(g) 28
Oil (g) 2625
Water (L) 23.45
Mixing Starts
12:55 PM
17.5kg of Vivek Agro & 17.5kg of Annapoorna Atta has been taken + Mixed 28g of Improver
7.6Kg of Water + Dissolved 490g Salt + Dissolved 210g of Sugar
Added 875g of Oil
Clockwise rotation of spiral hook
After 5 Mins
Anticlockwise rotation of spiral hook
Added 875g of Oil
After 5 Mins
Added 375g of Oil
After 5 Mins
Added 750ml of Water
Added 375g of Oil
After 5 Mins
After 5 Mins
After 5 Mins
Mixing Ends
01:27 PM
(Additionally Mixed for 2 Minute)
50
Proving Starts
01:28 PM
Proving Ends
01:53 PM
Chapathi Making
01:54 PM
Compression plates temp has been set with Top 180°C & Bottom 170°C
After dividing, the dough was pressed/compressed with the required pressure &
temperature. The Chapathi will be passed through a fan attached to the conveyor for
cooling(1-2 Mins).
Finally Rice flour will be sprayed onto the chapthi which is kept on the attached siever. This
is to avoid the stickiness of chapathi with one another.
06:30 PM
Printing
Sealing of Packets
Once required no of Chapathis were filled in the packs, packets were heat sealed and
verified.

Dough has been kept for proving more than the actual
Dough was not completely covered during proving
Temperature of compression plates are not stable, Keeps fluctuating ± 20-25°C
Found variations in size which ranges from 7.9-8.6 Inches in a same chapathi. So bit irregular
in shape.
Differences in process from the last two trial
Entire batch has been mixed in slow RPM except for 1-2 minutes
The spiral hook rotation direction has been changed clockwise & anticlockwise for every 5
Minutes
51
Fourth commercial trial

Whole Wheat Chapathi Trial
16-08-2022
Recipe
Atta (kg) 25 kg
(Vivek Agro &
25 kg
Annapoorna)
Salt (g) 300g
Sugar(g) 700g
Improver(g) 40g
Oil (g) 3750
Water (L) 33
Mixing Started @25 RPM

11:32 AM
25kg of Vivek Agro & 25kg of Annapoorna Atta has been taken + Mixed 40g of Improver
11Kg of Water + Dissolved 700g Salt + Dissolved 300g of Sugar
After 3 Mins
Added 1249g of Oil
After 3 Mins
Added 11kg of Water
After 3 Mins
Added 1254g of Oil
After 2 Mins
Anticlockwise rotation of spiral hook for 15 Sec
After 4 Mins
Added 10kg of Water
After 5 Mins
Added 1247g of Oil
After 2 Mins
Anticlockwise rotation of spiral hook for 15 Sec
After 5 Mins
Anticlockwise rotation of spiral hook for 2 Mins
After 3 Mins
Added 1Kg of water
Mixing Ends
12:06 PM
Total Time Taken: 32 Mins
52
Proving Starts
12:06 PM
Proving Ends
12:21 PM
(Chapathi making starts)
Total time taken : 15 Mins
Chapathi Making
12:21 PM
Compression pressure has been set at 3.5 bar
Compression plates temp has been set with Top 180°C & Bottom 170°C
After dividing, the dough was pressed/compressed with the required pressure & temperature.
The Chapathi will be passed through a fan attached to the conveyor for cooling(1-2 Mins).
Finally Rice flour will be sprayed onto the chapthi which is kept on the attached siever. This is
to avoid the stickiness of chapathi with one another.
01:35 PM
Total time taken: 1Hour 16 Mins
Printing
Sealing of Packets
Once required no of Chapathis were filled in the packs, packets were heat sealed and verified.
53
Parameters
Compression Pressure 3.5 bar
Temperature 180 TOP | 170 BOTTOM
Batch details
Batch Size 50 Kg
Mixing Time 32 Mins
Proving Time 15 Mins
Chapathi Making time 75 Mins
Total Output/50 Kg
Total no of Chapathi output 1425 No.
Accepted Chapathis
Total Acceptable chapati 972 No.
Acquired % 68.21
Chapathi Rejections No.

Machine 1 149
Machine 2 174
Machine 3 63
Machine 4 67
Total rejections 453
Rejection % 31.79
Chapathi Rejections Causes

Improper shapes
Improper Texture - Holes & Dots
Breakage in Chapatis
Size

(Repeated from First Commercial Trial)
Mixing is not proper & not uniform
Salt/Sugar RM should be sieved before using
Training needs to be given to the workers regarding proper sorting & fastening the work to
avoid foldings
Temperature set point must be 180/170; | Max ± 20°C |
Temperature of compression plates are not stable, Keeps fluctuating ± 20-25°C
Kneading should be done as suggested to avoid dots/holes in the chapathi
Compression plates needs to be wiped with cloth
Dough needs to be filled properly into the compression cylinder to avoid improper shapes
54
Arman Chapati- Sensory report

05.08.2022 Chemical analysis : (P+1)
Parameters Standard Trial
Moisture content (%) 39±2% 40.08%
pH 6.0-6.4 6.8
Remarks : pH found to be higher than the
specification
Dimensions:
Parameters Standard Trial

Diameter (inch) 8.5- 9 8.5-9
Thickness (mm) 1- 1.2 1.0-1.15
Sensory evaluation (P+6)
Ranking 1 2 3 4 5 5.25 5.5 5.75 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7
Dislike Dislike Dislike Neither Like

very moderately slightly like Like Like moderately very
much nor slightly much
dislike
Colour/ 1,2
Appearance
Aroma 1,2
Stickiness 2 1
Taste 1,2
Mouthfeel 1,2
After 1,2
cooking
Overall 1,2
acceptability
55
Key: Sample 1: Arman Chapathi (6-8 deg C)

Sample 2: Arman Chapathi (10-12 deg C)
Comments:
1.Colour and appearance was good.
2.Taste and mouthfeel was good on P+7 and P+8.
3.Thickness of chapati was found to be acceptable. Slight unevenness observed.
4.Puffing was observed during cooking and acceptable in chapati.
5.Chapati was good till P+8 days, No mould growth or foul smell noticed.
Note: Product acceptability limit >6.5
P+7th day (6-8 deg C) P+7th day (10-12 deg C)
Shelf Sensory Remarks

Life Score
P+1 6.4 Chapati puffs well, sensory found to be good and acceptable
P+3 6.35 Uneven thickness noticed in 3 amongst 10 chapati, sensory found to be
acceptable
P+4 6.4 Sensory found to be acceptable, puffing noticed in chapati
P+6 6.3 Sensory found to be good and acceptable
P+7 6.15 Sensory found to be acceptable
P+8 6.15 Sensory found to be satisfactory, observed puffiness is slightly less
Conclusion: .
⚫ Thickness to be maintained uniformly.
⚫ Shelf life of the found is found to be P+8.
⚫ Sensory and product stability holds good for P+8.
Market declared shelf life to be P+6 in chilled condition at temperature 5 degree celsius
56
NPD
Risk assiment for Arman Chapati
Process flow :
Batch Mixing Dispensing Dough Dough Resting Set the Machine

(Raw Material) RM Blending for 10-15min to standards
Packing in pouch Cooling (2 min) Dough Pressing Dough Ball Feed the dough
& Half cooking Making (50g)
Risk assisment:
1. Raw material: If the raw material are not with in specification, this may hamper production and
finished product and shelflife.
2. Moisture content: If the chapatis are not cooked 30% there may be chances of mould growth in the
final product in shelflife period.
3. Temperature of plates: 180 deg C top plate and 170 deg C Bottom plate has to be maintained, there
should be 2g moisture loss after cooking the product.
4. Stacking: should maitaine the stacking height of pouch as the pressure increases the chapati will get
intacted
5. Gluten Formation: In dough prepration process we have to check for gluten formation in the dough,
this will cause holes in chapati.
6. Thickness of chapati: As per specification 1-1.15mm thick the chapati should be maintained and
thickness should be uniform in chapati.
57
58
59
Chapter 11 Document Lists
Documents to be filed & Shared on daily basis:
1. RM & PM receival checklist (Whenever receiving RMs & PMs)
2. RM testing/analysis requisition form (Whenever samples are sent to Anekal for
analysis)
3. RM & PM issuance register – Inventory report
4. Personal Hygiene checklist
5. Batch Sheet
6. Sanitization checklist
7. Production process checklist
8. Chapati Weight checklist
9. Chapati diameter verification checklist
10. Packaging process checklist
11. Chapati pack weight checklist
12. FG Sensory checklist
13. Vehicle inspection checklist
14. Product dispatch checklist
15. PDI checklist
16. Shelf life sample record
17. RCA CAPA records
60
SOPs
TABLE OF CONTENTS
Chapter No. Title Page No.
1. Procedure for controlling outsourced activities

2. Procedure for master control of documents
3. Procedure for handling consumer complaints
4. Procedure for incident & crisis management
5. Procedure for control & handling of nc finish products
6. Procedure for conducting training
7. Procedure for tracking of training effectiveness
8. Procedure for personal hygiene practices
9. Procedure for medical checkup
10. Procedure for product recall
11. Procedure for measuring auditing skills & competenc
12. Procedure for corrective action plan
13. Procedure for preventive action plan
14. Procedure for maintenance & retrievals of record
15. Procedure for control of documents
16. Procedure for approval of incoming material and release of fg
17. Procedure for conforming finished products
18. Procedure for traceability
19. Procedure for change management
20. Procedure for glass handling
21. Procedure for cleaning, sanitization & housekeeping
22. Procedure for IPM
23. Procedure for management review program
24. Procedure for food defence
25. Procedure for purchase
26. Procedure for storage & warehousing
27. Procedure for air monitoring
28. Procedure for sampling plan
29. Procedure for hygiene
SOPs
30. Procedure for fumigation & fogging

31. Procedure for chapathi sampling plan
32. Procedure for sensory evaluation
iD Fresh Food India Pvt Ltd
Arman Foodtech Pvt. Ltd DOC NO; AR/SOP/001
Manufacturer; Whole wheat chapati
PROCEDURE FOR CONTROLLING OUTSOURCED ACTIVITY Date of Release 28/08/2022
Purpose:
To ensure the control of outsourced activities which are performed by Arman Foodtech Pvt. Ltd.
Scope:
Outsourced activities to be done inside and outside the Plant premises.
Responsibility:
QA (FSTL):
• Establish and execute the schedule to test Raw Water, Finished Product, and Effluent from
outside laboratories in accordance with FSSAI requirements.
• Appoint Pest Control Operator to ensure Pest free environment in the plant and premises.
• Appoint Certification Body to carry out audits as per certification guidelines and to ensure
proper implementation of Food Safety Management System.
• To ensure Supplier and Vendors are as per the Approved Vendor List provided and approved by
Food Safety Team and Customer.
HR Manager:
• Appoint labor contractor for executing skilled and unskilled workers in the factory.
• Liaison with Statutory and Regulatory Bodies.
• To appoint civil works to implement the online and scheduled work.
• To employ services of the transporter to provide properly conditioned vehicles.
• To evaluate the transportation cost economical to the company.
• To ensure the transport service is in convenient to the customer.
Production Manager/Operators
• Establish and execute the schedule to calibrate thermometer, pressure gauge, and weighing
balance from outside agencies.
• To appoint Mechanical and Electrical Contractors to implement the online works.
• Establish and execute the schedule of the Annual Maintenance Contract to perform maintenance
activities of equipments from outside agencies.
PROCEDURE FOR CONTROLLING OUTSOURCED ACTIVITY Date of Release 28/08/2022
PROCEDURE FOR CONTROLLING OUTSOURCED ACTIVITIES:

• To ensure that the source is an authorized entity, a dealer or distributor must have authorization /
License from the customer to act on their behalf.
• To verify the credentials of the service provider for the reliability and efficiency of services for
his performance.
• The service provider must show a valid document of his compliance with legal requirements.
• The cost parameters need to be evaluated against the service rendered. The evaluation is
necessary to be done by the department head.
• To ensure that the agreement is signed by both parties with respect to the terms and conditions
of payment and service.
• The agreement should have a clause of penalty in case the services are not in accordance with
the terms of the agreement. It must specify clearly the terms of breaking the contract in case the
situation arises so.
• To verify the services by the service provider are in accordance with the agreement.
• In case of appointment of Pest Controller Operator (PCO)-
1. All service technicians of PCO shall be well trained from external accredited agencies &
training certificates shall be in place.
2. PCO shall not be authorized to store Pest control chemicals inside our factory & premises
3. All service technicians who are officially deputed for Arman Foodtech Pvt. Ltd. shall be
covered under the life insurance policy & documents shall be in place with QA.
4. PCO is responsible for timely treatment, audit, and periodical trend analysis of all pest
observations.
5. PCO shall follow up for compliance of raised gaps in audit to ensure no pest harborage
inside factory & premises.
6. All pesticides and MSDS shall be in place which is used in treatments with a definite
concentration and frequency.
PROCEDURE FOR MASTER CONTROL OF DOCUMENTS Date of Release: 31/08/2022
Purpose:
Information on all Quality Management system-related documents is available in one place.
Scope:
The master control document contains all Quality Management system-related documents having
information like document number, no. of copyholders, issue date, revision date & no., and
document classification.
Responsibilities:
Manager – QA / Executive – QA (FSMS) has overall responsibility for establishing and
maintaining all the information in Master Control Document.
Procedure:
All the information about quality management system documents is recorded in the following form.
Document Document
Sr. No. Issue Date Revision Date Revision No. Remarks
Name No
PROCEDURE FOR HANDLING CONSUMER COMPLAINTS Date of Release: 31/08/2022
Purpose:
To monitor consumer contacts and ensure actions are taken to satisfy consumers and protect the
Company Trademark.
Scope:
Manufacturing Facility & Market
Responsibility:
Top Management, Manager – QA Sales Manager, Customer Care & Executive –QA.
The above Management staff has individual specific functions to be done. These functions are
detailed below:
Top Management:
• Take all necessary and possible action to eliminate or reduce the probability of recurrence of the
underlying cause of problems that comes under the Manager’s control.
• Ensure forwarding of all consumer contact reports and all product/package/fragments/materials
properly identified to QA for integrity review.
• Ensure any serious cause of concern to be routed through IMCR process.
Manager – QA/ Executive-QA:
• Acts on the situation become incident.
• All technical laboratory analysis work to be done in stipulated minimum time of 24 hours.
• To do traceability studies and verify them to the nature of complaint.
• To verify the process parameters and moderate, if necessary.
GM-Sales:
• Routine handling of consumer concerns.
• Follow-up with other competitive brands' consumer responses.
• Follow-up with technical / sales/laboratory analysis.
• Report generating for management review.
• Consumer Response Program.
• Liaison with consumer bodies.
• Handles the legal cases in coordination with legal bodies & region/division legal-in-charge.
• Responsible to handle or pass the consumer complaint reports to the consumer response
coordinator. If possible resolve the situation.
Definitions:
Consumer : One who consumes our product or has the potential to do so.
Customer : One who buys our product for re-sale.
Concern : Anything that the consumer or customer cares about relating to our product.
PI : Product Integrity concerns
NPI : Non-product Integrity concerns
CR : Consumer Response
CCE : Customer care Executive
CRP : Consumer Response Program
ICMT : Incident /Crisis Management Team
Procedure – PI & NPI Concerns

• All PI and NPI concerns are taken up by CCE.
• When consumers/customers contact the Company, QA collects accurate details regarding the
concern, using the Consumer Grievance Sheet as a guideline.
• The collected details have to be documented using the “Consumer Grievance Sheet”.
• QA will convey details as per Consumer Grievance Sheet to Manager –QA and Arman Foodtech
team for further investigation & resolution.
• If the concern is related to product integrity, try to collect the sample and ensure the product is tested
for Physico-Chemical & Microbial parameters & Test Report is generated in the prescribed format.
• The Concerns must be responded to within 24hrs locally and 48 hours if upcountry, from the date of
the complaint receipt.
• Sales contacting the consumer should try and retrieve the product and send it to the laboratory for a
Quality Assurance report.
• If the consumer is not willing to give the product, try and convince him/her and resolve the issue in a
fair and friendly way.
• Once resolved update the Grievance Sheet for OPEN/CLOSE status along with remarks.
• If the consumer turns into an extortionist, try to obtain a written request for the demand.
• Each unresolved concerns must be reviewed once a month end for the status of the complaint.
• If the complaint is unresolved for 6 months, then it will be considered resolved except for the legal
complaint which is to be handled by the company’s legal department.
• Management review meetings with the QA team every month; will take cognizance of Consumer
Concerns, together with a trends analysis.
• Each legal notice regarding consumer case/ FSSAI matters is to be referred to and should be answered
by taking help from the Company’s advocate.
Classification of PI & NPI concerns:

PI Concerns:
• Insects or Animal
• Tobacco Pouches
• Metal or Plastic materials
• Dirty or Sediments
• Mold or Fungus growth
• Faulty closure
• Off-taste or Spurious taste
• Date coding fault or MRP is not printed
NPI Concerns
• Stock or supply complaint
• New outlet request
• Sales or service request
• Sales generation assets complaints
• Thank you or compliment
• General enquiry
Consumer Response Objectives

• To respond to the needs of consumers/customers/distributors.
• To take proactive action to minimize the number of serious concerns.
• To inform and educate consumers through effective dialogue and other media.
• To identify underlying concerns.
• To take positive action to eliminate or modify the root causes of problems.
• Resolve individual problems before they become issues
Corrective Action Plan:

All the product integrity concerns where the product is obtained should be taken up in the device
action plan.
PROCEDURE FOR INCIDENT AND CRISIS MANAGEMENT Date of Release: 31/08/2022
Purpose:
The purpose of this procedure is to assess the risk (threat perception i.e. Risk In TACCP &
VACCP) of Arman Foodtech in terms of accidents, local environment, and business continuity
threats and to formulate a policy for taking necessary precautionary measures to avoid and
reactive measures to combat them. This document will spell out the process by which the local
management will assess the risk on the company trademark, image, infrastructure, people etc.
and prepare a plan to mitigate with the perceived/existing threats and prepare emergency
response and form an Incident / Crisis Management Team (ICMT) i.e., TACCP Team to deal
with the incidents as per the procedures decided and agreed upon to counter the threats.
Scope:
This program would help us assess risks and initiate actions for countering them.
Responsibility:
Manager-Production and QA-Executives are the owner of this program and are responsible for
-
• Formation of the Incident / Crisis Management Team.
• Imparting training to the members of the team.
• Identifying, Organizing, and checking the effectiveness of training imparted.
• Continuous monitoring to ensure that the systems are in place.
• Communication to all plant Associates, Region, and Corporate office on behalf of the
Incident Management team.
• Send reports of incidents to the Management as and when they occur.
Procedure:
Step-by-step instructions:
• Have a meeting of Dept. heads and form an ICMT for the Unit. The team should have
members who have sufficient knowledge of the local area and issues related to the local
area. It should also have members who have sufficient information and background of
the past incidents.
• Unit to ensure that the ICMT coordinator will train members of his Team.
• ICMT coordinator will nominate to work in his absence as Backup coordinator.

• Training program to focus on risk assessment for the unit in terms of, procedure and
understanding of crisis and threats to the trademark, infrastructure, people and business
Continuity.
• Formation of ICMT (Incident/Crisis Management Team), which is multifunctional with
outline responsibilities. In Arman Foodtech, Food Safety Team itself performs the role
of Incident/Crisis Management Team.
• Incident analysis+ is carried out and any event is responded to as per the procedure for
any incident or crisis.
• Review of incidents in monthly management reviews.
A systematic risk assessment by ICMT is to be done every month to identify and assess risk
events that may have an impact on their business as the first step in the asset protection process.
The following steps are followed:

• Identify Risk Events to be considered including TACCP and VACCP
• Assessing the likelihood of consequences and risk imposed by the Risk Events.
• Drawing up an action plan.
To identify Risk Events to be considered

The unit to identify risk events keeping in mind the incidents that might occur or have occurred
or potentially have some negative consequence on business. Once identified the risks to be
assessed.
Assessing the likelihood consequences and identifying the impact by Risk Events
In order to determine the likelihood of the risk, one should consider following factors.
➢ Whether the incident has happened before.
➢ Has the incident happened in other business units that has similar conditions?
➢ Any threats (direct, indirect) received from some groups which may be interested to
impact the business.
➢ The likelihood of any person or group to negatively impact the business.
➢ Attack from Militants
For each of the incident, are described for their likelihood of occurrence as Very High, High,
Medium, Low and Very Low, following are the guidelines as mentioned below.
Rating Description Impact Contact Activated

➢ The risk event is 1. GM - Operations
➢ Death of a person
Very expected to occur in most 2. Manager-
➢ Very significant financial loss
High circumstances and/or it is Production/Operators
➢ Loss of Image and Reputation
happening now. 3. QA - Executives
➢ The risk event will
probably occur in most
circumstances,
➢ A direct credible
➢ Extensive injuries to people
threat has been received 1. GM - Operations
➢ Very significant financial loss
and/or it has happened, or 2. Manager-
High ➢ Major embarrassment / harm
would have happened if Production/Operators
to reputation leading loss of
not actively prevented, a 3. QA - Executives
sales
number of times before
➢ The conditions are
very favorable for it to
occur
➢ The risk event might ➢ Significant injuries to people
occur at some time but requiring medical treatment
generally only under ➢ Significant financial loss 1.GM - Operations
specific circumstances, ➢ Moderate embarrassment to 2.Manager-
Medium
➢ Indirect threats have been image and reputation Production/Operators
received, leading to loss of sales
➢ The conditions could be over a short term
favorable for it to occur
➢ Minor injuries to people, some

➢ The risk event could First -aid treatment
occur at some time but is required
unlikely ➢ Minor financial loss 1. GM - Operations
Low ➢ No direct credible threats ➢ Minor embarrassment to 2. Manager-
have been received image and reputation to have Production/Operators
➢ Conditions are not a minor loss in sales for short
favorable for it to occur term
➢ No injuries to people
1. GM - Operations
➢ The risk event is very ➢ Very minor financial loss
Very 2. Manager-
unlikely to occur, ➢ No embarrassment or harm to
Low Production/Operators
exceptional image and reputation results in
no loss of sales.
Drawing up an Action Plan

Taking action means implementing effective asset protection strategies. This Strategy
is prepared after taking into consideration of the existing management practices. The Strategies
are prepared by ICMT keeping in view the various risks and the probable points or medium
from where the ICMT can get a feel of the probability of the incident happening so that
necessary actions can take in advance to safeguard our business interest.
Food Safety Team Leader is informed about all ICMT activities by ICMT coordinator. The
Crisis Management Contacts will be activated as per the level of impact caused by the risk.
Responsibility
Sr.
Name of Crisis Responses
No. During
After Working Hours
Working Hours
1) Inform Local power station.

Production Security In-charge to inform 2) Use backup power (Diesel Generator)
Long time power
1 Manager GM - Operations, QA-Executive Supply.
failure
& Production Manager 3) Stop the production. Reprocess the entire
product in process and in line.
1) Inform Local fire station / Police station

2) Use Fire extinguisher depending on cause
of fire by trained personnel
Major Fire, Security In-charge to inform
3) Isolate affected area
2 Explosion & GM-Operations GM – Operations, QA-Executive
4) Give first aid to injured person (if any) and
earthquake & Production Manager
send them to the nearest hospital
5) Inform to factory inspector, if any fatal
incidence.
1) Isolate affected area

2) Inform Local fire station / Police station
3) Give first aid to affected person (if any) and
send them to the nearest hospital
4) Inform to factory inspector if
Any fatal incidence.
5) QA chemist will affix Quality Hold Tags to
Security In-charge to inform
the Damaged product indicating that the
3 Accidents GM-Operations GM – Operations, QA-Executive
product to be verified for QA parameter and
& Production Manager
move product to secure storage location,
wherein it will not be released.
Record is maintained pertaining to the
disposed / released product with date & Date
of cases disposed / released reason for failure
and Corrective action.
Attacks by 1) Do not react or try to passivate.

external forces Security In-charge 2) Inform to police station
like Militants, to inform Production Managers, 3) Isolate affected area.
5 GM-Operations
Local groups or GM-Operations, Managing 4) Give first aid to injured person (if any) and
Labor revolt Director and Chairman send them to the nearest hospital
Non-Conforming
6
Product
1) Stop the production and immediately
isolate non confirmatory product that may be
affected.
2) QA-Executive will affix Quality Hold Tags
to the end of each pallet indicating that the
product is “Out of Specification” with respect
to the quality/packaging parameters and move
1) Before Executive QA to inform Manager
QA-Executive product to secure storage location, wherein it
Delivery - QA
will not be released.
3) Record is maintained pertaining to the
disposed / released product with the date of
manufacturing, time, no of cases disposed /
released reason for failure and Corrective
action.
GM –Operation GM- Sales will inform to QA

2) After Delivery will inform to Department and also notify the Refer Recall Procedure
QA Department Customer Care Manager
Plant Stoppage Production

Reprocess the product in process and in line
7 due to any of Manager/ QA- Production Manager – QA(A)
after QA confirmation.
above reasons Executive /
GM-Operations
1. Hold the product or material where
sabotage has happened.
2. Authorized concerns (QA) will verify
the things & then take decision of
product or material which has been
GM-Operations, sabotaged.
Manager- 3. Security alert will be initiated for
GM-Operations & QA-Executive,
8 Sabotage Production & all stringent access control and
inform to Manger QA
section surveillance on suspects.
authorities 4. Authority & responsibility will be
verified on the basis of sabotage for
all associate
5. All material which as per policy shall
be in lock and key will be verified for
its access control
1. Immediately Inform to the GM-
Operation By security Supervisor.
2. GM-Operation will coordinate with
Admin and IT Personnel to repair it
Failure of CCTV ASAP.
9. GM-Operations Security Team
Camera 3. Meantime Regular Security
personnel Round for that area, every
30 Min.
4. Close monitoring the nearby CCTV
Cameras.
1. Closely Monitoring the Security
guard’s activity by CCTV on
Mobile, whether taking round as per
schedule.
2. GM-Operations Daily Round of the
Security site or Facility.
10. GM-Operations Admin HOD
Negligence 3. Immediate action will be taken on
the security personnel for any
negligence by them.
4. Cross verification of the Activities
performed by them on daily basis by
HOD.
1. Immediately inform QA-Executive
and Production Manager.
2. Reject it if found Raw material or
Packing material or FG at any stage
of the process.
3. Inform to supplier for the same for
PRODUCT
11 QA Executive Admin HOD RM/PM and procurement Personnel
TEMPERING
in case of RM to do the RCA for the
same.
4. Proper rejected red color label is to
be put on the tempered product.
5. Dispose it off as per NC material
handling SOP.
PROCEDURE FOR CONTROL AND HANDLING OF NON-
Date of Release: 31/08/2022
CONFORMING FINISH PRODUCTS
Purpose:
To prevent the distribution and use of non-conforming materials in the plant.
Scope:
Raw Material, Packing Material, Intermediate Product, and Finished Product.
Responsibility:
GM-Operation is responsible for the final disposition of the material, and for communicating the
situation to the Manager Production/Operator/Executive QA.
QA - executives are responsible to conduct the physio-chemical & microbial tests wherever
applicable.
Manager – Production is responsible to interact with QA to receive QA testing reports for RM,
and PM, and if found any report is non-confirmatory then responsible to communicate with GM-
Operation.
GM- Operation is responsible to communicate to the supplier/vendor in case of any non-
conformity.
Associated peoples are responsible for carrying out the activities that support the program.
Definition:
Event: An Incident or series of Incidents that involve public health, public safety, product recall,
environmental or regulatory activity, risk to product or package integrity or image or which
might cause extraordinary loss of assets or create severely adverse publicity.
Procedure:
➢ Any product that deviates from FSSAI and Customer specifications is termed as non-conforming
product.
➢ Non-conforming products are to be segregated and labeled.
Handling of Non-Conforming Materials at Plant premises

• Identify the operational status of non-conforming material and handle in accordance with the
material status identification program.
PROCEDURE FOR CONTROL AND HANDLING OF NON-
CONFORMING FINISH PRODUCTS
• Label the product with proper communication note having the reason of rejection, product
identification, date coding details with date of rejection.
• QA - Executive communicates all information to the GM-Operation & Production Manager.
• QA-Executive approves destruction of non-conforming materials as per company’s guidelines.
Handling of Non-conforming materials at Market places

• The non-conforming products in the market place to be intimated by salespeople to respective
GM-Sales, Manager – QA, Production Manager, GM-Operations and QA-Executives.
• Management decides to disposing the same non-conforming products in the marketplace and/or
destructing in the plant premises in presence of QA-Executives.
• If the decision for destruction in the plant premises then follow the product recall procedure.
• If the decision for disposing of the products in the market place then it must be disposed of as
per the company’s guidelines.
Note: The Incident Management team will notify division of non-conforming Materials which
may potentially cause an incident situation or which may adversely affect the image of iD &
Customer Brands.
# Supplier is being communicated regarding the non-conforming product

6 iD Fresh Food India Pvt Ltd
PROCEDURE FOR CONDUCTING TRAINING Date of Release: 31/08/2022
Purpose:
To impart quality training based on gaps analyzed for associates thereby ensuring growth for the
individual in particular. As a result building capability in the organization to create a learning
environment.
Scope:
All levels of organization
Manager Unit:
He is the facilitator of the entire program. He is responsible for the identification of training needs
of all departments/associates at all level of organization and coordinates with FSTL & HODs for
the successful implementation of the training program.
Training Coordinator:
He coordinates training session as per the training calendar and schedules refresher training after
training evaluation by the trainer.
Procedure:
• Review individual job descriptions
• Create a skill set dictionary focusing on technical/behavioral and cross-functional competencies.
• Skill set dictionary includes desired levels of competencies with qualification statements for each
level.
• Assess gaps based on Supervisor appraisal, Performance review forms and self-appraisal.
• Validation of competencies
• Preparation of training calendar as per probable date.
• Respective HODs prepare the list of participants for the training program as per the schedule of
training calendar for the year.
• Training preparation is done based on the nature of program (Internal / External)
• Once the training is over, feedback is taken from the participants and proper documentation is done.
• Technical training evaluation records
6 iD Fresh Food India Pvt Ltd
PROCEDURE FOR CONDUCTING TRAINING Date of Release: 31/08/2022
Job Listing
List down all the jobs
Examine
prevalent in a unit Critically examine all
the respective job descriptions
for further competency
analysis.
Prepare a Competency
Directory
Preparation of a skill set directory
(Technical/Behavioral) covering all the positions.
Evaluation
Formats developed to evaluate every
associate on the skill sets at three tier level, i.e by
self, immediate supervisor and appraisal records.
Training Calendar
Need analysis matrix prepared on
the basis of two tier evaluation and1 past
years appraisal.
Methodology for checking the training effectiveness

Periodically, HODs & respective reporting heads evaluate the effectiveness of training by on-job
monitoring both for technical & behavioral skills.
PROCEDURE FOR TRACKING OF TRAINING EFFECTIVNESS Date of Release: 31/08/2022
Purpose:
To ensure that the manpower cost on training is effective and measuring the effectiveness of training
in terms of learning and its application, for the individual in particular and for the employee on the
whole.
Scope:
All permanent associates and contract labors in the unit.
Responsibilities:
GM– Operations: He is the facilitator of the entire exercise. This data helps him to prepare future
training needs and validation, manpower cost, and modifications in the present training.
Production Manager: He is responsible to coordinate the entire exercise and compilation of data
QA-Executive & HODs: On-the-job training review and post-training review
Procedure:
1. Once the training is over, the trainer will get the feedback form filled by the associates who
attended the training program.
2. A proper review of the feedback form is required to evaluate the success of the program or
customization in the future.
3. Behavioral training impacts are measured through job behavioral changes as perceived.
4. HOD feedback is ascertained for making an opinion on the success of intake.
5. The training balance sheet for every associate is to be prepared & reviewed with all HODs to
compare the level with an identified skill gap analysis to find out the level of competence on
the trained topic.
PROCEDURE FOR PERSONAL HYGINE PRACTICES Date of Release: 31/08/2022
PURPOSE
To provide guidelines for personnel practices to be followed by plant personnel, contract labors,
and all other persons entering plant premises and plant.
SCOPE
Plant and Plant premises
All plant personnel, contract labor’s, and visitors.
RESPONSIBILITIES
Respective HODs are responsible for the overall implementation of the program.
Executive – QA, is responsible to monitor the effectiveness of the program.
All plant associates are responsible for the implementation of GMP requirements.
PROGRAM DESCRIPTION
1. This program provides the guidelines for personnel hygiene practices to be followed at plant
premises.
2. Ensure all employees and contract labors know about the requirements of health and hygiene
practices, and personal protective equipment.
3. Medical check-up of permanent plant personnel is carried out annually and of contract labor six
monthly by a recognized medical practitioner. A medical checkup of any newly joined associate
has to be done fresh at the date of joining. (Refer to SOP for Medical checkup: PR/SOP-13)
4. Till the time a newly joined person is not medically tested, he is not allowed to join his/her duties.
5. A person who is found to be clinically free from contagious diseases is only allowed to enter
process areas.
6. The plant personnel is facilitated with lockers, uniforms, and toilets along with adequate water
facilities at hand wash stations.
7. Hygiene signs are placed at various locations in process areas and also displayed in hand wash
stations of individual sections.
TRAINING
PROCEDURE FOR PERSONAL HYGINE PRACTICES Date of Release: 31/08/2022
Plant personnel and contract persons, especially in processing areas are given training on Good
Manufacturing Practices and Personal Hygiene Practices six monthly.
Training evaluation is done as per Personnel hygiene and for plant personnel as per Housekeeping
and GMP audit.
CORRECTIVE ACTION
Personal Hygiene of the plant personnel is checked by the QA-Executive. Any major deviation
resulting in failing of Personnel Practices by any individual is brought to the notice of the
Production Manager and Concern Officer to take appropriate corrective action.
DOCUMENTATION
Personnel Hygiene Record: AR/CHK/007

PROCEDURE FOR MEDICAL CHECK UP Date of Release: 31/08/2022
Purpose:
In the food industry medical checkup of staff as per defined frequency (Annually) is mandatory.
Scope:
Pre-employment medical test for all new entrants, yearly medical checkups for permanent employees, and six
monthly for contract labors.
Responsibility:
HR/Operation Manager
Procedure
1. A pre-employment medical checkup is the responsibility of the employee to submit Medical Fitness
Certificate at the date of joining.
2. Annual Medical checkups to be done for permanent employees and for contract labor’s through a registered
medical practitioner by the employer.
3. The Medical practitioner issues a fitness certificate. Any critical observation upon any associate needs to
be dealt with utmost care with further medication in consultation with the medical practitioner.
4. No person with injuries or any communicable disease is to be allowed to enter the process area. Regular
checks are to be done by the hygiene officer and must be recorded.
5. All with an objective to maintain high standards of personal hygiene at the workplace.
PROCEDURE FOR PRODUCT RECALL Date of Release: 31/08/2022
Purpose: The purpose of this procedure is to define the requirements of conducting a Product
recall and to provide guidance on how to plan for conducting a Product Recall.
Scope: Plant and Customer warehouse
Frequency: 6 Monthly for Mock Recall
A recall is identified as Emergency Situation

Responsibility:
Manager - QA will be the “Recall Coordinator” for this activity.
Manager – QA: Overall responsibility to implement this SOP.
GM-Sales and Logistic Manager: To coordinate the activities of Product Recall.
Production Manager: To coordinate the activities of Recall in accordance to SOP.
Procedure:
Policy Traceability Requirements - To ensure all materials and products could be retrieved
from the supply chain if necessary. Production plant to ensure identification Code and labeling
of product for traceability from production batch number and date of production at the plant to
distribution and sale to specific customer locations. Identify to include:
➢ Finished product lot or batch number
➢ Production Date and Time
Confirm two ways traceability of materials used in products of the company to customer
locations.
Product Recall Plan:

Definitions:
Withdrawal - A product may be withdrawn from sale for two reasons:
➢ The product has a quality defect (e.g. odor or taste) or is underweight or has labeling
irregularities that do not pose a potential risk to public health and safety;
➢ As a precaution, stock may be withdrawn from distribution and/or sale pending further
investigation — if a risk to public health and safety is established, the product must be
recalled. Withdrawals do not require notification to statutory authorities or media.
Note – There is no withdrawal.
Recall - For the purposes of this Protocol, a recall is defined as ‘action is taken to remove from
sale, distribution and consumption foods which may pose a safety hazard to consumers.
➢ Such action may be taken if there is a reasonable possibility that use or consumption of
the food would cause adverse health consequences or even death. Examples: Presence
of Coliform or toxic chemicals or harmful foreign bodies in the finished product.
➢ Action may also be taken if the product has serious defects that pose a potential health
risk.
Remedial Action:
Permanent removal of unsafe products from the market or from use;
A recall involves notification to statutory authorities.
Conducting a product recall - There are three primary objectives in any food recall:
1. Stop the distribution and sale of the affected product immediately. Inform all the customers
to stop sale/ consumption and hold the product affected for recall within 24 hrs.
2. Inform the statutory authorities (all recalls) and the public (consumer recalls only) of the
problem within 24 hrs. Especially, FSSAI must be called as per the contact given in the
Incident/Crisis Contact List.
3. Effectively and efficiently remove from the marketplace any recalled product, which is
potentially unsafe within 24 hrs.
The aim of the Recall plan is to:

1. Stop the distribution and sale of the affected product;

2. Effectively notify associated customer’s management and appropriate authorities of the
recall;
3. Effectively and efficiently remove from the marketplace any product that is potentially
unsafe;
4. Effectively retrieve products from customer warehouses, retail stores, and/or consumers;
5. Effectively dispose of the unsafe recalled product;
6. Conduct a post-recall analysis and report on the outcome and effectiveness of the recall and
provide the appropriate authorities with an interim and final report on the recall; and
7. Implement a corrective and preventative action plan to prevent a recurrence of the problem.
Following the completion of the recall, the company will conduct a post-recall meeting to
evaluate the effectiveness of the recall.
Recall Coordinator is the person who is ultimately responsible for ensuring the correct
application of this recall plan. In the event that the company needs to initiate a recall, it is the
responsibility of the Logistic Manager to convene the recall committee and to conduct the recall
following the procedures outlined in this plan.
Recall Committee
The recall committee consists of the following people.
• Logistic Manager
• Manager – QA
• GM- Sales
• Production Manager
The recall committee is responsible for co-coordinating all aspects of a product recall and
ensuring all procedures are carried out thoroughly, and effectively.
The key steps in conducting a successful recall are:

A. Is a food recall necessary? – Convincing the recall committee.
B. Hazards / Risk Assessment
C. Informing the relevant authorities that a recall is or may be necessary.
D. Trade Recall - Stopping further distribution and sale of the product being recalled.
E. Retrieving the recalled product and product disposal.

F. Providing Business HR/GM-Operations, Manager-QA & Managing Director the final report
on the recall.
The Company may be informed of a problem with any of its products via the following
mechanisms:
1. Internal quality assurance testing indicates that there may be a potential problem with a
particular product or batch (e.g. microbiological results are above acceptable limits);
2. Customer complaints/feedback (e.g. phone call or letter informing sales department of a
potential problem by a customer or wholesaler);
3. A supplier of a raw material that is used by the company in making its products
Informs management that there is a problem with an ingredient; and
4. Government authorities, such as the police, local council, or health departments indicate that
there may be a problem with the particular product.
Determining Distribution of affected Product

The Regional GM-Sales is responsible for determining which States and/or Territories the
product has been distributed to, as well as other customers that may be affected. This
information can be obtained via customer invoice sheets that also note the lot identification
details and/or batch numbers of all distributed products sold to individual customers. These
sheets should be traced back to when the first delivery of the affected code took place. The
Regional GM-Sales is also responsible for contacting all affected customers by phone
informing them of the problem with the product.
Determining the quantity produced

The Regional GM-Sales in conjunction with the Manager – QA must also determine the total
quantity of the batch in question, which can be derived from the QA & production records
relating to the batch code and subsequent day of production.
The Production Manager is also responsible for conducting a stock take of the in-house storage
facilities and isolating any remaining stock that relates to the affected batch. This stock must
be placed on “HOLD”, be clearly identified as well as isolated so that accidental distribution
cannot occur.
Note - No stock is to be disposed of without clearance from the Manager – QA.
Retrieving the Recalled Product and Product disposal Retrieval

Wherever possible Company will take all reasonable measures to retrieve stock in the
marketplace and have it returned to the company.
It is the responsibility of the Regional Sales Manager and in conjunction with Logistic Manager
and recall committee to decide how the recalled product is to be retrieved from the distribution
chain and disposed off.
Records of the product lot identification details and the amounts of products returned from
customers and distribution centers must be kept.
Returned Product
Manager - QA is responsible for carrying out any further testing of the returned product if
required as well as ensuring any returned stock is clearly identified with a label and that this
stock is held in a separate area to prevent accidental redistribution. No stock is to be disposed
off unless clearance to do so is given by Manager - QA.
Disposal of Recalled Product
Manager – QA in conjunction with the Logistic Manager will assess the disposition of the
recalled product and decide the best method of disposal. The recalled product that is being
held, prior to disposal, must be separated from other product and clearly identified as ‘recalled
product’ and not to be used subject to further advice.
Providing the Managing Director with the final report on the recall
Manager - QA will prepare a final report on the effectiveness of the recall.
The report is to give information to the recall coordinator regarding the effectiveness of the
recall and what corrective actions have been taken both with respect to the recall and to prevent
a recurrence of the problem in the future. It is the responsibility Manager – QA to ensure all
members of the recall team in the course of their duties retain accurate records of relevant
information such as amounts of returned stock, amounts of stock unaccounted for, copies of
press releases, corrective actions taken, etc.
Manager - QA provides GM- Operations, Sr. VP-Operations & Managing Director the final
report with all the above information within 48 hrs. Copy of this report will be retained in the
Recall File.
Post recall meeting As soon as the Manager - QA will convene the recall committee to discuss
the effectiveness of the recall and to outline and put into effect strategies and preventative
measures that will prevent the problem from recurring again.
Items that will need to be addressed in this meeting include:
Conducting an audit of the process to identify hazards that have contributed to the cause of the
problem in the product.
Responsibility – Executive-QA
• Changes will need to be made to production and processing systems in order to prevent
a recurrence of the problem in the future.
• Reviewing, updating, and revision of written company processes and procedures and
ensuring that these changes are communicated to all staff through an effective change
management program.
1
PROCEDURE FOR MEASURING AUDITING SKILLS AND
COMPETENCY
Purpose:
Providing a standard operating procedure to measure the auditing skills before conducting
audit & evaluate their competency during the auditing process.
Scope:
Internal Auditor
Responsibility:
FSTL:
• Selecting the audit team.
• Organizing the training programs for the auditors(new process change)
• Preparing the audit schedules for the year.
• Communicating the audit notification to all departmental head & auditee.
• Conducting opening meeting.
• Allotting auditors to various cross –functional areas
• Assist the auditors during Auditing.
• Generating the audit report in support with objective evidence.
• Conducting the closing meeting.
• Ensuring the CAPA report generation within stipulated time of audit report handover.
• CAPA tracking & its effectiveness checking.
• Periodically reviewing auditors skills & competency
Definition:
Internal Audit: An internal audit is systematic and independent examination to determine
whether quality activities and related results comply with planned arrangements and whether
are implemented effectively.
Auditor: The individual or team who carries out the audit activities.
Auditing skills: Different techniques to conduct the audit process.
Competency: Able to control the auditing situation by staying focussed on the scope of audit.
Quality Management system: The collection of procedures, activities, organizational structures

and related documents establish to respond to applicable requirements by directing regulating
operation’s quality assurance activity.
Procedure:
Auditing Skills:
Selecting people to perform the audits are important because of training involved and time
needed to conduct and report each audit. Selection of an individual to management or own
1
COMPETENCY
the program is also critical to a smooth roll-out of program. There are no special criteria to
be the internal audit programmer owner.
Qualification Criteria or Auditors:

Any person can be selected for audit team, but he shall meet following criterias to perform
the audit. Those are:
• Trained to perform Audits

• Familiar with cross functional Operation to be audited
• Understand objective & scope of auditing
• Good communicator-both written and verbal
• Good listener
• Open minded
• Patient
• Analytical Skills
Some of the attributes added to the auditors skill is:
• Obtained & access objective evidence fairly.

• Remain true to the purpose of the audit without fear or favour.
• Evaluate constantly personal interaction during audit.
• Treat concerned personnel in a way that will best achieve the audit purpose.
• Perform the audit process without deviating due to distraction.
• Perceive situation in realistic way.
• Understand complex operations from a broad perspective.
• Commit full attention and support to the audit process.
Before conducting any of the above requirements, the auditor shall be trained enough
externally or internally by the trained external Auditors.
Competency Mapping of Auditor:
FSTL not only carries out the duties of planning & performing audit, but also strives to
maintain consistency between auditors and improve their performance so that audit results are
meaningful and lead to continual improvement through the operations.
Auditor’s competency mapping shall be maintained by:
• Ensuring knowledge of current standards & requirements.

• Ensuring knowledge of current auditing procedures and methods.
• Participating in refresher training wherever necessary.
• Having their performances reviewed at least every 2 years by an evaluation panel.
1
COMPETENCY
The comments on Auditors competency mapping is as follows:
Action Plan
Score Comments
More than 85 % Very Good Selected to conduct an internal audit
Competency level can be increased by conducting
Within 65-85% Average training of internal auditors.
Does not qualify for the audit

• To be selected for internal Auditing training by
external faculty
Less than 65% Poor
• Evaluated for training effective
• The competency mapping exercise to be
conducted during his first audit after training.
PROCEDURE FOR CORRECTIVE ACTION PLAN Date of Release: 31/08/2022
Purpose:
Providing a standard operating procedure to prepare & implement the corrective action plan in
order to eliminate the non-conformity & prevention of its re-occurrence in the Food Safety
Management System.
Scope:
Auditors, Departmental Head, Management Representative, Top Management & Associate
Responsibility:
Auditors:
• Conducting the activities of the audit to find any non-conformities in the system.
• Follow –up the Corrective Action Plan (CAP) activities to close the non-conformance
in such a way that it prevents its re-occurrence.
Departmental Head:
• Presenting the CAP for any process /system deviation.
• Ensure the CAP is issued at specified areas.
• Ensuring the effectiveness of corrective action plan before & after implementation.
Management Representative:
• Ensure the appropriate corrective action are placed in the system.
• Ensuring the effective implementation of corrective action plan within the system.
Top Management:
• Considering corrective action plan report is one of the inputs for management review
discussion being improvement opportunity tool.
• Reviewing the corrective action plan for its effective implementation.
• Providing the resources wherever required.
Associates:
• Intimating any process deviation observed or sharing good practices within the
operation.
• Responsible for implementation of corrective action plan.
• Giving feedback to the departmental head on its implementation.
Definition:
Continual Improvement: A tool to improve the Quality Management System.
Corrective Action Plan: An action taken to eliminate the root cause of an existing
nonconformity, defect, or other undesirable situation in order to prevent its reoccurrence.
Root Cause Analysis: Investigation of any problem /Non-conformance in the system through
5M tools (Man/Machine/ Method/Money or Maintenance) to find out the problem causes of its
occurrence.
Procedure:
Corrective action is critical component for the continuous Improvement process because these
activities are targeted at permanently fixing the root cause of existing or potential
nonconformities to the food safety management system.
The correction plan is derived through two different processes, those are;
• For any internal/ External audit findings
• For any process deviation through
1. By management
2. By associates
3. By Suppliers/visitors
4. By customers/consumers
5. By other resources
Some of the tools for effective implementation of a corrective action plan within the system
are as follows;
• Investigation
• Implementation
• Measurement
• Evaluation of its effectiveness
In the CAP tracking report, the above 4 points tracking is to be taken with dates of completion.
Investigation:
When any non- conformance observed in the system that is to be classified into various steps
and action plans are to be derived for:
• Process monitoring issues
• Internal and external audit findings
• Quality system issue
• Internal & external communication
• Environmental, health & safety issues
• Management review
• Equipment Maintenance
• Storage & handling of Ingredients products
• Products integrity of concern in the market from customers/ consumers
• Statutory & legal issues from the concerned authorities
Collect complete data and information that are required to sustain the problem. Also, collect
all the relevant data that may be useful to analyze the root cause. The collection of data and
information also depends on the next step. Which is analysis. Many times the possible analysis
method that is appropriate will decide on the data/information requirement. The QA tools can
be used for collecting & analyzing data.
The problem can be analyzed in number of ways. There is no single method that is best fit for
every situation. The analyzer will choose appropriate methods below to analyses the Situation
• Though Past Experience

• Applying Statistical tools
• Consulting the subject matter expert through internal or external sources
• Trial and error method
• Conducting more tests to conform the process for eliminating the non- conformities.
Every non-conformance must not activate the corrective action plan which will lose its
efficiency and focus. The corrective action plan is only issued to the non-conformance which
is having significant impact on the operation in the sense of food safety i.e. all major & critical
non-conformance.
The non-conformance that are easy to analyze and can be implemented on the spot. Such
problems are addressed through a quick fix method (All minor non-conformities) and are not
part of root cause analysis process expect it all action plan are to be addressed with justified
root cause analysis by the group of people associate to the problem.
The root cause analysis can be derived based on 5 Ms for raising the CAP are as follows:
• Man
• Machine
• Method
• Material
• Money or Maintenance
Action plan for Audit findings (internal/External)

• After getting audit report respective departmental heads are responsible for deriving the
roots cause analysis & corrective action plan with deadlines and responsibilities
assigned.
• The departmental heads with other respective management are responsible to decide
the type of action plans , Quick fix action plans & root cause analysis (as & when
required ) in order to close the NCs
• The action plan with root cause analysis report, for Critical & Major NCs are to be sent
back to the auditor/QA Manager for checking the effectiveness of action plan & root
cause analysis. In case of minor audit NCs action plan needs to be sent to auditors /QA
managers for follow up. In case of external findings forward the same to division
auditors for verification.
• The housekeeping audit findings are not needed to be taken for corrective action plan
since all those are quick fix in nature.
Action plan for the process deviation:
• All process deviation corrective action plans are addressed in respective programs are
standard operating procedure whenever required.
• The process deviation, with root cause, CAP needs to be documented in the RCA &
CAPA Records.
• Action plan for all NCs, action plan to be documented in RCA & CAPA format.
Implementation:
The necessary corrective action plan with or without root cause analysis is to be considered for
the implementation to eliminate or prevent its re-occurrence, the concern associates &
departmental head are responsible for implementing the same.
Measurement:
• The corrective action plans are to be measured with the proper objective evidence.
• The action plans are to be tracked in every week (only for critical & major) for effective
implementation of action plans.
Evaluation for its effectiveness:

• Departmental heads are responsible to monitor & evaluate the effectiveness of action
plan & to prevent its re-occurrence by using the measurement as objective evidence to
check the same.
• The CAPs are only being called as closed when it tracked with proper evidences based
on management.
• The audit findings, action plan & its measurement with evaluation are to be taken as
input in management review. The appropriate comments / suggestion are also
considered for the improvement of process
Records:
RCA & CAPA Records.

PROCEDURE FOR PREVENTIVE ACTION PLAN Date of Release: 31/08/2022
Purpose:
Providing procedure for preventing non-conformance in the system for continual improvement.
Scope:
Auditor, Departmental Head, Management Representative, Top Management & Associates
Responsibility:
Auditor:
• Conducting the audit activities to find out any non-conformities in the system
• Follow-up the PAP activities to close the non –conformance in such a way that it prevent its
re-occurrence.
• Suggesting improvement opportunity/observation in the system for continual improvement.
Departmental Head:
• Preparing preventive action plan for any process /system deviation.
• Ensure the preventive action plan is used at specified areas
• Creating the preventive action plan for the process /system
• Ensuring the effectiveness of preventive action plan before & after implementation
• Adopting the good practices/sharing/knowledge/discussion being a part of preventive
action plan
Management Representative:
• Ensures the appropriate preventive actions are placed in the system.
• Ensure the effective implementation of preventive action plan within the system
Top Management:
• Considering preventive action plan report is one of the inputs for management review
discussion being a improvement opportunity tool.
• Reviewing the preventive action plan for its effective implementation
• Providing the resources wherever required.
Associates:
• Intimating any process deviation observed or sharing good practices within the operation.
• Responsible for implementation of preventive action plan.
• Giving feedback to the departmental head on its implementation
Definition:
Continual Improvement: a tool to improve the quality management system
Preventive Action Plan: An action taken to eliminate the root cause of potential nonconformity, defect
or other undesirable situation in order to prevent its reoccurrence
Root Cause Analysis: Investigation of any problem/non-conformance in the system through 5M tools
(Man /Machine /Material/Method/Money or maintenance) to find out the probable causes of its
occurrence.
Procedure:
PROCEDURE FOR PREVENTIVE ACTION PLAN Date of Release: 31/08/2022
Preventive action plan is a plan to improve the system rather than waiting to have a non-conformance
in the system
The steps of preventive action plan is much similar to corrective action plan
Investigation
Identifying & analysing the process to evaluate the preventive action plans in order to improve the
system.
The preventive action plan can be sourced from different areas as follows;
• Learning from the process can be sourced from different areas are as follows;
• Sharing good practices for internal /external sources.
• Recommendation from suppliers/visitors/customers/consumers
The identified processes which are used for preventive action plan are;
• Providing feedback to supplier based on incoming material inspection.

• Feedback from Internal QA analysis report for better result
• Preventive Maintenance
• Sanitation program to prevent microbial growth
• Destructing /disposing the NC/trademark materials to prevent environment pollution
• Analysis & evaluation to prevent failure of product /process
• Monitoring the storage & handling of finished product /ingredients/intermediate product to
prevent spoilage
• Tracking the documents to prevent any un-controlled documents in use.
• Maintaining & tracking the records for traceability of the product
• Contingency plans for conserving the resources.
• Suggestion schemes for system improvement
Implementation:
Implement preventive action plan effectively for effectiveness of the system.
Measurement:
Each action plan shall be measured and analysed to ensuring its effective implementation.
Evaluation for its Effectiveness:

All preventive action plans are to be evaluated and checked against their performance
PROCEDURE FOR MAINTAINANCE AND RETREVALS OF
RECORDS
Purpose:
Providing a standard operating procedure to Maintain & retrieve the operational and laboratory
records
Scope:
Entire manufacturing process operations
Responsibility:
Manager-QA/Executive-QA (FSMS) and Departmental Head are responsible for the
overall effectiveness for this activity. They shall maintain all records related to sanitation,
Quality Assurance and process parameters.
The production Manager/Operators shall maintain all production records in coordination
with Executive-QA for preventive and operational maintenance records.
All associates are responsible for executing the activities.
Procedure:
1. All records are maintained for a period of 1 year.
2. It is to be reiterated that all obsolete records after the period specified for its retention
such records in presence of FSTL need to be destroyed in a confidential manner.
3. For softcopy retention records, delete the copies from the server.
PROCEDURE FOR CONTROL OF DOCUMENTS Date of Release: 31/08/2022
Purpose:
To have standard operating procedure for controlling, issuing and withdrawal of documents within the
Food Safety Management System.
Scope:
Documents affected areas
FSTL/ Manager-QA, Executive-QA , All departmental Heads & Documents Users
Responsibility:
FSTL/ Executive-QA are responsible for monitoring and controlling the document management
program.
• Issuing the current & updated documents to the user.
• Ensuring that the controlled documents are available with all users.
• Effective tracking mechanism established for ensuring the easy traceability.
• Setting an effective retrieval system to prevent any misuse or obsolete document reference.
• Ensuring the document control & distribution system effectiveness.
GM –Operations and Production Manager is responsible to carry out the activities in the
absence or in tandem with FSTL/Executive-QA.
Executive-QA is responsible on overall effectiveness of food safety Management System. Also

responsible to control the classified documents.
All user associates are responsible to follow the current & revised documents.
Departmental head is responsible for ensuring the implantation of current documents by end
users.
Definition:
Controlled Documents: The documents which is under custody of Manager-QA for easy retrieval
of documents which help to update with current & updated document.
Uncontrolled Documents: The doesn’t require control is uncontrolled document.
Procedure:
This procedure addresses on the following requirements
• Document Control
• Document Issue
• Document Distribution
Document Control
Controlling the Internal Documents:
• Master Control Documents (QMS Manual and Food Safety Manual) will be controlled by
Executive-QA (FSMS).
• Controlled Manual copies will be with GM-Operation, Manager-QA, Executive-QA,
Production Manager.
• All the above officials will have full access to the documents.
• Form, checklists will be considered as record after filling appropriate data /information and can
be controlled by the respective department heads.
• Based on copy holder declared in MCD (as per decision of departmental head), hard copy will
be distributed to the user along with the sign of the department head.
Controlling External Documents:
• All external documents including supplier manuals, OEM Manuals and customer quality
manuals are listed in document management system along with document type, document
name, document category to be controlled by Manager-QA/FSTL.
• Executive-QA ensure no reprinting of documents is allowed at any stage, by keeping all
soft copies of QMS Documents inaccessible to other users. Also as Management
Representative will be responsible for the control of documents of external origin and will
work cross functionally.
Document Issue:
• When any documents newly created and/or changed, departmental Head decides the
no of copy holders affected to his document and accordingly provide current version.
• Executive-QA (FSMS) will take the acknowledgment from the requesting person along
with all related personnel affected to the document.
Document Distribution:
Distribution of Internal Documents:
• The master control documents is (content of all Food Safety Management System documents)
having all details of hard copy holders.
• The hard copies (Food Safety Management System documents) with signature of Manager –
QA (FSMS) and GM –Operations are to be distributed to the users.
• Executive –QA (FSMS) and Production Manager are responsible to ensure replacement of
obsolete documents as & when the document revised.
Distribution of external Documents:
• The Placement & document as per the external documents list (Ref: DM/LST-15) will be
controlled by Manager- unit HR and E& HS Asst. Manager For document categorization refers
Document Management.
• All relevant users can access document from the original location with permission from HOD.
• Accessing control can be decided by the departmental head for any external documents.
• Document Owner/Manager-QA (FSMS) is not responsible for any copying of external
documents.
• It is not essential to have hard copies of external documents with a sign of Manager –QA &
GM-Operations.
PROCEDURE FOR APPROVAL OF INCOMING MATERIALS &
RELEASE OF FG
Purpose:
To carry out in house testing of all incoming materials & FG for QA clearance as per defined
specification.
Scope:
All incoming material & All FG
Responsibility:
QA-Executive are responsible for analysis of incoming material, storage of Chapatis in the
appropriate cold storage area & Dispatch as per defined specification.
GM-Operations are responsible to coordinate with security officer, Production Head and stores
concern regarding any deviation in challan or bill, material shortage, rejection and access of material.
He is also responsible for storage handling and to ensure that the accepted incoming material is only
used in order to FEFO.
Production Manager/Operators are responsible for manufacture
Manager-QA are responsible for overall effectiveness of SOP.
Procedure:
1. After incoming material reaches at the gate, GM-Operations checks challan and or invoice for
purchase order (PO) No. If found Satisfactory then stores concern gets intimated by security
officer to receive the material.
If he found deviation in PO No. of challan and invoice and actual PO No then he/she
intimates supplier for arrangement of challan and or invoice with correct PO No. and also
intimate security officer to receive the material.
2. QA- Executive inspect the vehicle for specific parameter defined in vehicle. Inspection
checklist related to food safety to ensure that material is not contaminated or damaged.
If vehicle noticed with contamination the QA- Executive rejects the vehicle and intimates
GM-Operations and concern departmental head regarding rejection of material.
If material noticed damaged then GM-Operations returns same and intimates suppliers
regarding rejection and return material in same vehicle.
If material found shortage or excess according to challan or invoice then GM-Operations
corrects challan or invoice with actual quantity along with verification sign of driver.
3. After thorough inspection of material vehicle and satisfactory compliance of checklist GM-
Operations shifts material into quarantine area and intimates QA-Executive to withdraw
RELEASE OF FG
samples for analysis and material remains in quarantine area till incoming material analysis
report gets issued from QA- Executive.
4. QA-Executive checks appropriate for COA and other mandatory certificates e.g., Food Grade
along with material shipment. If everything found in place then QA-Executive withdrawn
random samples as per defined procedure and take the samples for analysis.
5. After analysis if found in compliance with specified range of physic chemical as well as
microbial parameters as per defined specification, then QA-Executive gives clearance with
authorized sign. If results will not meet defined specification, then material will be rejected.
6. After receipt of QA report, GM-Operations will shift the material from quarantine area to
identified location in stores for that material, store concern puts bin card with appropriate
information contains Name of material, B.No. and Quantity followed with issuing of material
to concern departments as per their validated demands. Individual bin card is being placed for
individual batch.
7. In case of material rejection, GM-Operation is responsible to send material back to concern
vendor within 48hrs. Rejected material is placed in “NONCONFIRMING GOODS AREAS”
with appropriate tag contain name of Material, Batch No., MFG Date Quantity, Date & Time
of receipt with Authorized signed off.
8. GM-Operations and Departmental Head are responsible to monitor the usage of material in
their respective area shall be in order to FEFO through utmost care of hygiene aspect.
FINISHED PRODUCT:
1. After production Chapati products, FG should be storage in the cold room to be keep safe till
dispatch.
2. Samples to be taken from the day-to-day production as per the sampling plan of the FG form for
Chemical & Microbiological analysis.
3. Samples will be tested for the required Parameter to be tested as per the specifications and
results will be documented properly by Executive-QA.
4. After analysis if found in compliance with specified range of physical, chemical as well as
microbial parameters as per defined specification, then Executive-QA gives QA clearance with
authorized sign of Manager-QA.
5. In Case of FG Results are not matching any of the specification or desirable characteristics the
product will be immediately put “ON HOLD” For Further Analysis (Resampling and retesting).
6. Resampling done from “TOP, MIDDLE and BOTTOM” sample of the pallet or batch and
tested in duplicate or visual inspection for OLT will be done. If found the same result the product will
be rejected.
RELEASE OF FG
7. In case of material rejection, Production Manager is responsible to Cut Open it within 48hrs.
Rejected material is placed in “NONCONFIRMING GOODS AREAS” with appropriate tag contain
name of Material, Batch No., MFG Date Quantity, Date & Time of receipt with Authorized signed
off.
Records:
Vehicle Inspection Checklist : AR/CHK/008
Housekeeping Record : AR/CHK/016
RM testing procedure : Ref. Chap. 3 - Master document
COA Specification file
RM Issuance record/register
PROCEDURE FOR CONFORMING FINISHED PRODUCTS Date of Release: 31/08/2022
Purpose:
Providing a procedure for Handling of Non-conforming product in order to protect/preserve the
environment.
Scope:
Plant Premises, In-house rejection, Market Place, Market Return
Responsibility:
Manager-QA: Communicating with GM- Operations / GM-Sales on product/ material non-
conformances. Clearly segregating and labelling the non-conforming products in order to prevent its
reuse/misuse/dispatch.
GM-Operations/Manager-QA/Executive-QA: Intimate the customer on product non - conformance.
Definitions:
Event: An Incident or series of incidents which involve public health, public safety, product recall,
environmental or regulatory activity, risk to product or package integrity or image or which might
cause extraordinary loss of assets or create severely adverse publicity.
Procedure:
Handling of the disposition of Non-Conforming Products in the plant:
• Identify the operational status of non- conforming products and handle in accordance with
material status.
• When suspected non-conforming product is identified, notify to the Executive-QA and GM-
Operations.
The disposition can occur with the approval of Executive-QA at Plant Premises or Market Place by
dilution and then it is subjected to effluent treatment / handover it to authorized third party as
hazardous waste.
Handling of Non-conforming materials causes incident situation:
When any potential incident situation occurs follow Incident Management Program Ref. -
AR/SOP/004.
GM-Operations will notify incident/crisis management team regarding to occurrence of non-
conforming products, which may potentially cause an event. The communication shall contain all the
details of product information and the date code details with reason of non-conforming.
Note:
➢ Customer needs to be communicated regarding the non-conforming product, if and when
required.
PROCEDURE FOR CONFORMING FINISHED PRODUCTS Date of Release: 31/08/2022
DOCUMENTATION:
Disposal of non –conforming material :
DOCUMENT CONTROL:
Refer MCD
Market Return FG Handling Procedure Flow
Sales Or Marketing Team Inform to Dispatch Team for

Market Return with Complete Details i.e., Dispatch date,
PKD, UBD, Vehicle no., Route name, Reason of Return,
Quantity etc.
Security check & Entry of the Return Quantity at Main

Gate
Product unload & received at dock by Dispatch Supervisor
Dispatch Team has to Communicate to GM Operation and

section In-charge with Complete Details i.e., Dispatch date,
PKD, UBD, Return Date, Reason of Return, Quantity etc.
Return FG to be transferred to the Respective Section after

getting instruction from Section In-charge
Section In-charge will Inform Head-QA with Complete

Details i.e. Dispatch date, PKD, UBD, Return Date, Reason
of Return, Quantity etc.
Executive QA Performs Sampling & Testing (Chem./Micro)
Composite sample of the Market Return by Executive QA

For Quality testing
QA Executive Communicates to Section In-charge about the

Quality of the return FG
Joint Decision will be taken based on the product Quality

by QA Head and Section In-charge for further appropriate
action (Whether Reuse or Dispose or Resale )
PROCEDURE FOR TRACEABILITY Date of Release: 31/08/2022
PURPOSE:
To trace the raw material and or Ingredient origin used to manufacture a specific batch of finished
product.
SCOPE:
All raw materials and or ingredients used in manufacturing of finished product.
RESPONSIBILTIES:
Executive – QA is responsible to monitor the effectiveness of the procedure in stores area.
All Associates are responsible to implement the procedure.
REFERENCES:
From iD Fresh Foods traceability procedures
Frequency: 6 Monthly
DEFINITIONS:
Upstream Traceability: All ingredients are tracked up to the FG (by vendor) batch number.
Downstream-Internal Traceability: One full batch of Raw /Packing material is tracked from reception
to the finished products.
Downstream –External Traceability: One finished product is tracked until change of ownership, i.e.
until the entity to which it has been invoiced.
Backward Traceability: It shows tracking of FG from storage stage in manufacturing up to RMPM

receipt.
Forward Traceability: It shows tracking of FG from storage stage up to distribution details of specific
batch no. through sale invoices and stock in SAP.
PROCEURE:
Traceability studies are done to trace the component used for manufacturing the finished product. The
traced component can be cross verified for their quality parameters and its use to manufacture the
specific batch of product under consideration.
The raw materials and ingredients used for manufacturing of products –Whole wheat chapathi are listed
below.
1. Chakki Atta
2. Sugar
3. Salt
4. iD improver
5. Refined Sunflower Oil
In Arman Foodtech Pvt. Ltd. responsibilities of various departments are established to achieve 100%
traceability of product manufactured.
A. Stores:
From material receipt to issuance to concern departments, the records are maintained in
stores as mentioned below:
1. Batch No.
2. Date of Manufacturing
3. Date of Expiry
4. Quantity
5. Date of Receipt
6. FASSAI Compliance
7. Food Grade certificate
Also RM issuance record is maintained for individual material with all the details maintained above
to harmonize the issuance system.
B. Production:
1. At the time of receipt, production concern cross verify the issuance slip from stores for
above-mentioned parameters and if found everything physically as per issuance slip
then it will be accepted in production day stores.
2. Production maintains dedicated record of traceability for individual Material which
includes :
a. Batch No.
b. Received Quantity
c. Date of Manufacturing
d. Date of Expiry
e. Date wise usage and closing
f. Product variety With batch code
3. Batch code of specific product is the end point of traceability procedure so from batch
code of specific batch, traceability can be done (Supply Chain Backward).
4. Specifically for Chapatis, traceability is being followed according to flow charts
designed and implemented mentioned below.
Whole wheat Chapati
Process Physical Record
Receiving of all Check Quantity

ingredient at production and Lot No. of
area given by Production receiving ingredients
Manager/GM-Operation. in issuance note.
Record quantity of
Use desired quantity of each ingredients and lot
ingredients (As per no. in batch sheet
recipe) in production of At run end (Daily),
Whole wheat chapati take stock during closing,
reconcile.
NOTE:
Stock re-conciliation to be done on daily basis & if there is a big difference of
actual versus log sheet against standard, then RCA to be done
Pouches (PM)
Process Physical Record
Receive pouches in Check issue voucher for

PROCEDURE FOR CHANGE MANAGEMENT Date of Release: 31/08/2022
1. Purpose
⚫ The purpose of this procedure is to provide the guidelines on how changes that an impact
on the Quality & Food Safety Management System may have should be managed,
communicated, agreed and controlled.
2. Responsibilities
⚫ It is the responsibility of the management at iD Fresh Food and plant head of any iD fresh
unit to ensure full compliance with this document.
⚫ Unit QAs and Employees will continue to be trained, instructed and supervised to ensure
necessary understanding as well as implementation of this SOP
⚫ The stake holders, initiator and the owner is responsible for the proper implementation of
this SOP
3. Scope
⚫ This procedure applies to the changes in the system, process & procedures,
equipment/machinery, statutory/regulatory, Raw materials, packaging material, product,
vendors, key person & premises associated with the manufacture of the food products
4. Associated Records
⚫ Change card/ Technical risk management card
5. Procedure
⚫ Process change should be initiated by the process owner/the initiator( proposing the
change)
⚫ All technical changes, of whatever size and whether temporary or permanent, must be risk
assessed before work commences.
⚫ Risk Assessment for technical changes must include quality, food safety, Associate safety
aspects and Environmental and Operational risks.
⚫ Risk Assessment must involve a team of stakeholders involved in this process.
⚫ CC & TRM form should be issued by the security/ Admin and a tracker for the issual
should be maintained
⚫ The completed CC & TRM form will be submitted to QA by the owner for filing and
accountability
Key roles in the process mentioned in this document are:

Type of
Requestor Owner When Stakeholders
change
1. When product quality is
affected Production,
1. Production R&D 2. Issues during process Purchase,quality,
3. To improve the quality logistics
Raw
material 1. Non availability Production,
QA Purchase 2. Vendor issues Purchase,quality,
logistics
Production,
1.to improve product quality with
R&D R&D Purchase,quality,
different RM
logistics
1. Change in specification to
improve quality & sensory Production,
2. Change in ingredients Purchase,quality,
Production R&D
required to improve quality & logistics, R&D,
sensory logistics
3. Customer requirement
Product
Production,
1. Shelf life issue
Purchase,quality,
Quality R&D 2. Sensory quality
logistics, R&D,
improvement required
logistics
Production,
1. To increase the shelf life
Purchase,quality,
R&D R&D 2. To improve sensory
logistics, R&D,
quality
logistics
1. When in need of
QA, Production,
improvement
Production QA facility, purchase,
2. When there is a change in
logistics
system
1. Regulatory/statutory
requirement
Process 2. Identify change
& requirement during audit/
Procedures verification
QA, Production,
QA QA facility, purchase,
system
logistics
4. If the existing procedure is
not efficient
5. For better outcome &
safety
6. To improve PRP based on
monitoring
7. Continuous improvement
1. When in need of
improvement
QA, Production,
2. When changes required in
Facility Facility facility, purchase,
the frequencies
logistics
3. When the existing
procedure is not adequate
1. Faced issues form the
existing equipment/ machine
2. When there is a change in Facility,QA,
Production Facility
procedure/ process production
3. When there is any
Equipment additional requirement
/
1. When an existing
machinery
equipment is not in good condition Facility,QA,
Facility Facility
2. when the capacity of production
existing equipment is not sufficient
1. When identified hazards in Facility,QA,
QA Facility
the existing equipment production
statutory/r 1. When changes are required QA, Production,
QA QA
egulatory from regulatory facility, purchase
1. When product quality is
affected QA, R&D,
Production QA/ R&D 2. When found issues with purchase,
the stability production
1. Non availability QA, R&D,

Purchase Purchase 2. Vendor issues purchase,
Packagi production
ng 1. Complaint history
QA, R&D,
material 2. When the food is affected
QA QA purchase,
by the packaging material
production
3. Customer complaints
1. Issues with the raw
material
2. Based on complaint Production,
production Purchase
history purchase, QA
process or product
1. When there is an issue in
Vendors delivery
Purchase Purchase
2. No stability in delivering
the raw material
1. Failure in the supplier audit

QA Purchase 2. Complaint history
Key 1. Due to resignation HR, respective

HR HR
person 2. Internal transfer department
1. When there is a shift in the
Manageme premises required
Premises Management All key departments
nt 2. Change in premises required due
to increase in the business volume
6. REVISION
Sl. No. Revision Date Revision Reason Revised by Approved

details by
PROCEDURE FOR GLASS HANDLING Date of Release: 31/08/2022
Purpose: To prevent Contamination of product due to glass breakage in the process area.
SCOPE:
The procedure describes actions to be taken in the handling of glass in case of breakage in the
warehouse/processing areas and usage of static glass in Arman Foodtech Pvt. Ltd.,
REFERENCES:
• iD Fresh Foods Good Manufacturing Practices
RESPONSIBILITY:
Role Responsibility for corrective actions

Glass breakage in the production area Production
RM/PM Warehouse
Replacement of broken Glass Engineering
PROCEDURE:
Application Preventive Measures

Windowpanes / Door Glasses All glass panes in following areas should be covered with
safety film: In all High Hygiene ,Medium Hygiene areas
& In following Basics Hygiene areas :
• Warehouses
• Dress / Shoe change areas
• Standardisation / Chemical handling Area ( for
wet mix ingredients )
• Any other area identified through HACCP study.
• All new installations shall be polycarbonate ( in
lieu of policy to avoid glass in production areas.
Glass Bulbs / Tube lights All tube lights / dome lights / bulbs in following areas
must be covered / filmed: In all High Hygiene , Medium
Hygiene & In following Basics Hygiene areas:
• RM /PM Warehouses
• Corridor areas ( Adjacent to main door )
• Standardisation Area
( for wet preparation)
• Any other through HACCP.

Glassware in line lab All glass ware in line lab must be accounted. Periodical
verification (once in 3 months) must be done to ascertain
number of glassware pieces of each type.
PROCEDURE FOR GLASS HANDLING Date of Release: 31/08/2022
Sight glasses Wherever possible these should be replaced by

polycarbonate or Perspex.
In case this is not possible the glasses should be of shatter
proof safety glass type.
Each process area must maintain a list of such glasses.
Glass Thermometers Glass & Mercury thermometers are not allowed in process
areas. These must be replaced by electronic devices.
Actions in case of Glass Breakage
Glass Breakage in Process / Inspect the area

Storage area
Collect all glass splinters, Is the breakage

carefully (Don’t touch with bare hands) in close vicinity of
open line/ product?
Y N
Report the breakage to shift o
es
officer & co-mfg incharge
Stop the line &
segregate the product
Ensure that broken

glass pieces are retrieved. Do joint
inspection with
Hygienist / QA Rep.
Y N
Get the glass replaced es o
from Engineering Refer to
preventive measures in page Impacted product /
2 material shall go for
incineration.
PROCEDURE FOR CLEANING, SANITIZATION &
HOUSEKEEPING
PURPOSE:
To define requirements and procedures for cleaning & sanitizing process equipment following
recommended methods and frequencies for the entire plant and premises producing Chapati.
SCOPE:
Areas covered under the scope of cleaning & sanitation activities.
Personnel involved: Equipment operator, QA Executive and Production Manager.
RESPONSIBILITY:
Equipment Operator: Responsible to carry out cleaning & sanitation activities as per defined
method. And to preparing the equipment and carry out the applicable the CIP process.
QA Executive: Responsible for monitoring the effective implementation of the defined guidelines in
the production areas. And ensuring overall effectiveness of the program. Also, Ensuring adherence to
all the requirements of cleaning & sanitation program
Cleaning:
The cleaning and sanitizing system where detergents, sanitizing agents, and water are circulated
through appropriate equipment’s by wiping and spraying without the need to dismantle any
equipment.
Sanitizing:
The treatment of clean surfaces and equipment by a process that destroys pathogens and substantially
reduces the population of all other microorganisms.
PROGRAM DESCRIPTION:
The equipment covered under cleaning & sanitation activities in the unit are broadly classified as
follows:
➢ Equipment surfaces those are in direct contact with food.
➢ Equipment those are in direct contact to external surfaces of the finished food package.
Equipment surfaces those are in direct contact with food:
•To ensure processing equipment is free of contaminants, all the equipment need to be cleaned
and sanitized daily after use.
• Five step cleaning & sanitation ( C.I.P. ) Process of above category equipment on daily basis
and C.I.P. on periodic interval basis.
• Above mentioned cleaning and sanitation methods are in daily practice with below listed
equipment from Chapati.
A. Whole Wheat Chapati Document No.
1. Weighing scales and equipments
2. Mixing machine
3. Proving table
4. Chapathi Making Machine
5. Plates
HOUSEKEEPING
Equipment those are in contact with external surfaces of the product package
Crates
PURPOSE:
To ensure all areas of plant and plant premises are kept clean and organized to protect the quality and
integrity of materials handled and to reflect a positive image of the company.
SCOPE:
All areas of operation including the entire plant and warehouse, machinery and plant premises.
Responsible personnel: Plant associates of concerned areas.
RESPONSIBILITIES
Executive – QA is responsible for the effective implementation of the program.
All associates are responsible for monitoring the housekeeping in their respective areas.
Food Safety Team is responsible for conducting monthly audits to assess the housekeeping conditions.
All associates are responsible for keeping their work areas neat and clean.
Executive-QA is responsible to communicate audit results to the departments audited.
PROCEDURE:
The program is focused on design and implementation of a housekeeping program relevant to the
facility. All housekeeping checklist are maintained to facilitate the process.
The Housekeeping schedule of the entire facility is divided in 6 sectors as given below:
1. Outside Grounds and Facilities;

• Floors
• Gates
• Strip curtains
2. Reception;
• Security cabins
• Tables
3. Hygiene Station ;
• Washbasins
• Mirror
• Soap and IPA dispensers
• Fly Catcher
• Hand Dryer
• Floors
4. Sieving area ;
• Door
• Floor
• Walls
• Shifter
HOUSEKEEPING
5. Mixing area
• Door/Strip curtains
• Mixer
• Tables
• Utensils
• SS Containers
• Floor
• Walls
6. Chapathi making area ;
• Door
• Floors
• Tables
• IPA dispenser
The different areas which fall in the above categories Production Manager and concerned
equipment operator are responsible for the housekeeping of that area.
TRAINING:
1. On-job training should be given to the associates who perform the job.
2. Classroom training sessions should also be conducted for all associates to create
awareness about GMP and Housekeeping.
RECORDS:
Master Cleaning & Sanitation Records.
DOCUMENT CONTROL: As per MCD – Chapter 14

PROCEDURE FOR INTEGRATED PEST MANAGEMENT Date of Release: 31/08/2022
PURPOSE:
To provide a procedure for control of pests and thereby preventing the contamination as well as
destruction of materials.
SCOPE:
Plant & Plant premises, Pest control coordinator & service provider
RESPONSIBILITIES:
Pest Control Operator is responsible for spraying of pesticides in the plant, premises and monitoring
of rodent bait station/glue pad stations.
Executives-QA are responsible for monitoring the activities and ensures that chemicals used for the
pest control do not contaminate the product as well as the product contact surfaces.
Manager - Production is responsible for ensuring the implementation of program and to establish
corrective action plan in case of any deviation
Executive-QA is responsible for overall effectiveness of the program
PROCEDURE:
1. Production Manager, GM-Operation, Executive-QA, Manager-QA and Pest Control Operator
conduct a joint assessment of plant & plant premises before finalizing plant specific pest
control program for
▪ Surrounding grounds and Facility perimeter.
▪ Plant Building (Processing areas) exterior.
▪ Interior areas of the Plant and Warehouse.
2. Training is provided by Pest Control Contractor to key plant personnel.
3. The frequency of spraying & the insecticides/pesticides to be sprayed are as provided by
division. Placement of rodent bait stations and glue pad stations are mentioned in pest control
Facility Diagram.
4. MSDS of the chemicals used are provided by pest control personnel.
5. Quarterly audit will be carried out by pest control personnel.
6. Pest Control is carried out in the plant and plant premises as per division guidelines, as given
below:
Sr.No. Treatment Frequency Target insect / rodents
1. Fly Control Treatment Daily & as and when House Fly/Flies/Midges

required
PROCEDURE FOR INTEGRATED PEST MANAGEMENT Date of Release: 31/08/2022
2. Rodent Control Fortnightly & as when Rats, Mice and

Treatment required Bandicoots
3. Disinfection Treatment Bi-Monthly & as when Spider & Lizards, Gold
required Cockroaches, Red &
Black Ants, Silver fish
and American
Cockroaches
TRAINING:
Training is conducted by service provider on pest control system, Do’s and Don’ts to pest Control
Coordinator and the key personnel in the plant where pest control is crucial and chances of cross
contamination is high.
CORRECTIVE ACTION:
1. Pest Control Agency personnel will be informed in case of any deviation and corrective
action will be taken after consultation with Sr. Manager-QA
2. MSDS sheets are to be seen and applied in case of accidental ingestion or inhalation of
pesticides.
3. Pest Control Agency will conduct audit of whole premises quarterly and submit the audit
report with detail corrective action plan to be established by the organization.
Reference:
DOCUMENT CONTROL
As mentioned in MCD
PROCEDURE FOR MANAGEMENT REVIEW PROGRAM Date of Release: 31/08/2022
PURPOSE:
This program is designed in accordance with the company policy of continual improvement. In order
to achieve continual improvement. In order to achieve continual improvement top management of the
company will review all the quality system related issues and all key operational parameters at
defined periodic interval through management review meeting.
SCOPE:
Food Safety and Quality Management system as per FSSC22000
RESPONSIBILITY:
FSTL is responsible to drive the process in coordination with all other departmental heads, GM-
Operations and food safety team.
PROCEDURE:
In the Food Safety Management Systems, the policy is set for the organization and the objectives are
derived to fulfil the company’s policy. Also, the objective splits in to different objectives in respective
functions / areas /department. All the above specified objectives are on line to achieve organization’s
objective.
The Quality and Food Safety Policy along with objectives are defined in QMS Manual.
Management reviews are conducted at minimum of six-month frequency to ensure continuing
implementation, suitability, adequacy, efficiency, and effectiveness of Food Safety Management
system. It makes Food Safety Management System dynamic; without these reviews system may
become ineffective over period of time. Plants process change, customer’s market change and people
change – these changes require modifications in the FSMS. Regular management reviews ensure the
FSMS is still suitable, adequate and effective in changed environment.
Management representative of the company carries out review of FSMS at a minimum of six-month
frequency. This review is conducted to ensure the continuing suitability, adequacy and effectiveness
of the FSMS. Opportunities for improvement and need for changes are also identified during these
meetings. The meetings are attended by representatives (department head) from different departments.
Objectives of the Management Review are;
• Establishing FSMS is achieving the expected results and meeting Company’s requirement,
continuing to confirm the standards in accordance with the established operating procedures
• Confirming continuing satisfy the customer needs and expectations by evaluating the
customer feedback and complaints.
• Reviewing the Internal/external audit findings and identifies /realizes the areas of recurring
problems and potential improvements.
• Deriving the corrective action plans for the non-conformance findings by proper root cause
analysis.
• Evaluating preventive actions plans by analysing the FSMS & finding the potential non-
conformance.
• Checking the effectiveness of previous corrective actions and review the adequacy and
suitability of the QMS for current and future operations of company.
• Follow up action plans from previous review.
• Quality policy & Quality objectives revision /modification.
• Ensuring the adequacy of resources provided & training needs to achieve the Quality & Food
Safety objectives.
• Change & recommendations for improvements in FSMS.
• To review performance of the process & conformity of product to find out possible areas for
improvement.
• To expose irregularities or defects in the system, identify weaknesses and evaluate possible
improvements.
• Evaluation & analysis of business loss & profit.
• Ensuring the environment is free of pollution and safety is available at every aspect to
safeguard the people & property.
Management review input;

• Audit results
• HACCP plan, validations
• CAPA plan & its tracking
• Customer feedback & its evaluation
• Incidents /Crisis Management
• Follow up actions of previous MRM
• Process performance
• Quality NCs & action plan
• Changes affecting QMS performance
• Total Quality Management
• Conformity of raw and packing materials /Intermediate/finished products
• Supplier performance
• Training Compliances
• Suitability of policies and objectives
• FSMS status & recommendation /suggestion for improvement
Management review outcomes;

After the review, management representative prepares the minutes of meeting with action plan as
decided and distribute to the department heads. The management Representative keeps track of
implementation and the follow up activities
Corrective action:
Corrective action must be initiated based on situation .QA tools and other management tools like
cause & effect diagrams. All formal corrective actions need to be taken accordance with plant
corrective action program.
Records:
Records maintained for this program is in the minutes of meeting for specified corrective actions
in the Management Review Meeting.
PROCEDURE FOR FOOD DEFENCE Date of Release: 31/08/2022
PURPOSE:
To ensure that the food processing facility is secured from potential vulnerabilities that could
adulterate or contaminate the finished product through contamination of raw materials, in-process
formulations, or finished products at the end of the production process.
SCOPE:
Plant & Plant premises
RESPONSIBILITY:
GM- Operation and all Departmental heads
PROGRAM DESCRIPTION:
The first step is to develop a functional food defense plan that assesses the existing security measures
and risk reduction programs in place to reduce the likelihood to adulterate or contaminate the
finished product through contamination.
In the development of the food defense plan, the establishment will look at where the vulnerabilities
may arise. These may be from outside through the incoming raw materials, through unauthorized
entry or through the water supply, or they may be through internal means such as employees that have
access to raw materials and ingredients, in-process formulations, or even finished products.
After the establishment identifies potential vulnerabilities, it will then examine possible risk reduction
methods such as the use of physical security or hardware (e.g. Alarms, doors, guards, and access
control systems), personnel security (e.g. Background checks, screening, training and awareness) or
procedural security.
Once the key vulnerabilities are addressed with risk–reduction methods, the establishment needs to
ensure that the risk–reduction techniques are being used (e.g., doors are kept locked, and visitors are
not allowed into the plant without prior permission. The staff should be trained and vigilant in the
access control in the process area.
Details of Establishment:
Facility Name : ARMAN FOODTECH PVT. LTD.; MANUFACTURER; WHOLE
WHEAT CHAPATI, BANGALORE.
Facility Location : No 11,12 OFF HOSUR ROAD, SINGASANDRA, BOMMANAHALLI, B
B M P SOUTH, BENGALURU, KARNATAKA - 560068.
Area of Facility : ___ SQ. METERS
Product : WHOLE WHEAT CHAPATI
Hours of operation : 24 Hours × 7 Days Every Week
Primary Customers : iD Fresh Foods
Number of employees and visitors of the facility at any given time: 200 Approx.
FOOD DEFENCE PLAN

Date of completion of this document: 31.08.2022
Food Safety Team is entrusted with the job of the Food Defense Team. They are responsible to
implement the program given in this document:
Do you have a select supplier program in place?.........Yes

The approved Supplier List is provided by iD Fresh Foods. They have evaluated each of the suppliers
to select supplier programs with criteria like sampling and testing and auditing the manufacturer’s
facility wherever required. Proper certification and product information with MSDS if applicable is
provided by the supplier.
If yes, raw material supply is covered by a select program of the following:
List of Raw Materials
1) List of raw materials & Ingredients : Yes
2) Package type : Yes
3) QA checks are done on the raw materials and ingredients : Yes
Cleaning and Sanitation Chemicals

List of chemicals being as specific as possible : Yes
Package type should define how the chemical is received : Yes
Provide details on product storage, e.g., locked in a cage, unlocked in storage room,
Locked in bulk storage tank : Yes
Cleaning & Sanitation staff internal- Yes External (Contracted) : Yes
Controlling Access to the Establishment & Operations : Yes
Are non-employees always escorted in the establishment : Yes
Are truck drivers kept out of food storage & preparations areas? : Yes
Are barriers (locked doors, fences) in place to prevent unauthorized entry in to the
grounds, building and operation areas? : Yes
Are limited–access areas secured? : Yes
Processing Steps & QA Checks Step : Yes

Raw material receiving QA check : Yes
Ingredient receiving QA Check : Yes
Handling of raw materials by people QA check : Yes
In-process holding QA check : Yes
Packaging QA check : Yes
Analysis of Food Defence Plan
After documenting the background information on employees, access facility and operations,
raw materials and ingredients, finished products, chemicals and sanitation operations, raw
materials and ingredients, finished products, chemicals and sanitation operations and
processing steps
Areas Reason for vulnerability Critical Node Yes or No
1. Employees Lack of identification : No
2. Uncontrolled access within plant : No
3. Unsupervised activities : No
4. Non-employees Lack of Identification : No
5. Uncontrolled access within the plant : No
6. Unsupervised activities :
No
7. Raw material suppliers not part of select supplier program : No
8. Opportunity for unsupervised access during receiving or storage : No
9. Ingredients supplier not part of select supplier program : No
10. Opportunity for unsupervised access : No
11. Processing unsupervised access to raw materials during processing : No
12. Unsupervised access to open hoppers, tanks or other vessels during operations : No
13. Chemicals & Sanitation Unsupervised crew : No

14. Unsupervised access to raw materials, ingredients & finished product during cleaning
operations : No
15. Unlocked storage of chemicals : No
16. Other access to water supply : No
TRAINING:
Training will be provided to all plant permanent employees along with the contractual peoples
on regular basis or as when required.
CORRECTIVE ACTION PLAN:

Corrective action plan would be initiated whenever any non-conformity is observed during
plant run or at the time of audit
PROCEDURE FOR PURCHASE Date of Release: 31/08/2022
Sr. No. Activity Reference

1 Indent from Sales / Procurement Team
Indent is received from the Sales / Procurement Team. Evaluate the indent and
justifies the final incident which is forwarded to Arman Foodtech Pvt. Ltd.,
2 Enquiry for quotation

After the receipt of the indent GM-Operations performs market visit if the
purchase is local for the required materials or makes his searches through website
and take the information about the material and asks for quotation from various
vendors.
3 Quotations from various vendors are coming as per demand
Various vendors submit their quotations by mail, fax, or post.
4 Inspection of vendor done according to capacity, and food safety norms
Inspection of vendor is done by GM-Operations/Executive QA and samples along
with the specifications are submitted to Executive-QA. If it is related to Food
packaging material, raw material, or any ingredient material then it is inspected as
per food safety norms and if it is found to be correct then the further process is
carried out. For local common purchases, the above procedure is deleated.
5 Quality Aspect for Approval - Vendors are approved according to their quality,
timely delivery, and food safety rule follower and are supplying the goods with
affordable rates.
The QA Dept. checks the sample and its specification if it matches our quality
plan the vendor is approved if the fails to norms the vendor is rejected
6 Approval for vendor
After the confirmation from Executive-QA and Manager-QA is received, the
vendor is categorized and added to the approved list.
7 Purchase Order preparation by purchase executive. verified /signed by Assistant
Manager Purchase.
8 Purchase Order is verified & 7 Approved sign by GM-Operations.
9 The purchase order is final and Approved by GM-Operation or Business Head if
required.
10 The Approved purchase order is to be sent to the vendor through post, mail or fax.
A purchase order along with the required documents/payment terms /specification
/desired date/delivery location is communicated with the supplier.
11 The deliveries are checked properly and again the samples are checked by
Executive-QA that whether the material is as per the specification or not. Once
the samples are as per standards the material is accepted and unloaded.
12 If the material is rejected, should inform the respective vendors and the material
has to be replaced immediately.
PROCEDURE FOR STORE AND WAREHOUSING Date of Release: 31/08/2022
PURPOSE:
To ensure a system complies with the Integrated Management System during receipt, storage,
issue, and accounting of raw material, packing material & general material.
SCOPE:
Raw material, packing material, engineering material, and general material.
RESPONSIBILITY:
Gm-Operation is responsible to implement store function as per defined SOPs
Executive – QA is responsible to deliver acceptance /rejection decisions of incoming

material within time as per the defined SOP.
Production Manager – is responsible for the monitoring of store activities on daily basis to
ensure their compliance with the Integrated Management System
GM-Operation is overall responsible for the performance of stores as per defined SOPs and
for its compliance with the Integrated Management System
Safety Measures:
1. Vehicle Movement: The driver must drive the vehicle according to the defined speed of
“10 KM/HOUR” and be alert on the turnings with the help of convex mirrors to have safe
movement of the vehicle.
At the time of parking in premises, it is mandatory to guide the vehicle by security guard
along with vehicle cleaner a per defined yellow colour markings and “STOP” signages.
2. Use of PPEs to ensure safety: it is mandatory to use ISI mark helmet, safety shoes and
safety belt (Tested for weight) for staff and contract labours to perform the assigned task.
Safety belt use is mandatory in case of height works and the belt shall be hooked to a rigid
surface to ensure safety while performing assigned tasks. Use of a ladder inside stores is
mandatory while approaching upper shelves of material storage racks.
3. Lifting heavy load with a hand pallet truck is mandatory and the same shall be placed on
the lower side of material storage racks.
4. Slippery Conditions: Due to oil or chemical spillage or any other activity e.g., cleaning of
floors with detergents, it is mandatory to have “Slippery Area” signage in place.
5. In case of confined space works, it is mandatory to have “Slippery Area” signage in place.
6. All chemicals shall be placed in a dedicated area under lock & key and shall be handled
very carefully according to their physic-chemical properties.
7. Material Safety Datasheet (MSDS): it is mandatory to have all MSDS in place to overcome
emergency
8. Store shall be equipped with strong doors along with access control and shall always be in
lock & key when not in operation
9. Stacking of material shall be as per standard height. Generally heavy material shall be in
lock & key when not in operation.
10. It is mandatory to take care of all the above safety measures while implementing the
below procedure.
PROCEDURE:
FOR MATERIAL INWARD:

1. After arrival of incoming material at main gate, security supervisors check
material shipment for proper challan or invoice along with purchase order (PO)
number followed with communication to Gm-Operation.
2. Security supervisor provides stamp on inward no., Vehicle no., time and date
challan or invoice and further guide vehicle for parking at the dock for unloading
of goods.
3. GM-Operation checks vehicle thoroughly as per defined parameters in vehicle
checklist and record observations along with the driver’s signature on the same
4. GM-Operation further checks PO copy along with the ordered quantity and
challan quantity followed with the presence of COA of received material.
5. Then the material is unloaded on the dock and brought to the store. Said material
is being kept in a quarantine area with a” HOLD-Release” tag till receipt of QA
clearance from
Executive-QA.
6. Goods receipt note (GRN) is prepared for each bill of all incoming material within
24 hours and the same is submitted to the accounts department for final billing.
7. After receipt of QA clearance, the material is being stored in its identified place in
the rack as per FEFO
8. In case of material rejection from QA, GRN is cancelled and rejected material is
sent back to the vendor within 48 hours.
9. Store supervisor updates received material details in store inward register on daily
basis.
➢ FOR STORAGE OF MATERIAL:

“The term storage refers to the physical act of material placement in store on pallets,
shelves and racks etc. with the objective of their issuance later to end user with FEFO
application. The purpose of store is to provide and user right material in right quantity
at right time”
1. Store team is committed to the maximum utilization of space with “NO
COMPROMISE ON SAFETY AND QUALITY”
2. Material is being placed on identified pallets, shelves, racks along with
appropriate batch-wise bin cards which ensures easy identification of the material.
3. Store In-charge / supervisor monitors placement of material in its identified place
with FEFO application.
4. All materials are being protected against temperature & humidity abuse (As per
storage norm), pilferage and pest infestation with adequate infrastructure and
integrated pest management
5. Entire store is fully equipped with adequate lighting to ensure a safe working
environment and the Temp. & Humidity must be below 30°C & 65 %
respectively.
➢ FOR ISSUANCE OF MATERIAL:
1. End user department raises material requisition of required material along with sign of
departmental head.
2. Store supervisor issues right material as per material requisition form and generate
material issue slip with the name of the material, batch no., and issued quantity. In
case of material issued with multiple batch nos. with different quantities, it is being
clearly mentioned on the material issue slip to end-user department.
3. Store supervisor strictly follows FEFO in issuance of material to end user department.
4. End user department verifies material as per material requisition form for material
required, issued quantity and batch no. If found any change in requisition and
issuance, it is being settled in store or in production floor with correction and sign off
wherever necessary.
5. In case of material balance at end of the day in end user department, it is being stored
in one day store and necessary care is being taken by end user department. End user
department generates material requisition form in next date according to opening
balance of material/materials in one day store.
RECORDS:
1. Vehicle Inspection Checklist : AR/CHK/009
2. RM Issuance register
PROCEDURE FOR AIR MONITORING Date of Release: 31/08/2022
PURPOSE
To check the microbiological quality of air as per iD Fresh Foods standards.
SCOPE
This standard gives methodology for sampling & microbiological analysis of air for Enumeration and
aerobic plate count (APC) and yeast and mould count (YMC).
RESPONSIBILITY
Microbiologist
Executive – QA; To ensure the sampling plan is followed.
INTRODUCTION
Air quality inside the Chapati processing area influences the microbial quality of Chapatis. Chapatis
are susceptible to contamination by airborne microorganisms. Microbial air quality is a critical point
in the processing of Chapati product since air borne contamination reduces shelf life and may serve as
a vehicle for transmitting spoilage. Airborne micro-organisms in the plant include mainly bacteria and
yeast moulds. The main sources of airborne organisms in the Chapati processing area include the
activity of factory personnel, Chapati making equipment, floor drain, ventilation, and air condition
system, packaging material, and water. Microbiological analysis of air involves 3 main steps which
are sampling, analysis, and enumeration. Air sampling can be done by sedimentation (settle plates).
Air is generally analysed for aerobic plate count (APC) and yeast and mould count (YMC). The APC
and YMC are employed as of indicators of hygiene and sanitary conditions of the environment in
production, processing, and storage area.
PRINCIPLE
Sedimentation (settle plate technique used for determination of APC and YMC in air. In this
technique, the selective solid agar medium in the Petri plate expose in the process section/production
area. The petri plates are then incubated at a specified incubation temperature for specified periods of
time. After the incubation period, the colonies developed in each plate are counted and the count
express in CFU/ 15 minutes.
EQUIPMENT AND GLASSWARE
Autoclave - For wet sterilisation of microbiological media. At 121°c/15 PSI for 15 min.
Discarding Autoclave - For decontamination of biohazards in Petri plate after taking count at
121°c/15 PSI for 30 min
Hot air oven - For dry sterilisation of glass Petri plate, used at 165 ± 5°c for 3 hrs
(LAF) - For preparing aseptic media Petri plates for microbiological analysis.
Incubator – For incubation of Petri plate of TPC (37 ± 1°c) and YMC (25 ± 1°c)
Weighing balance – For the weighing of media
PROCEDURE FOR AIR MONITORING Date of Release: 31/08/2022
PREPARATION OF MEDIA PLATES AS PER MANUFACTURE INSTRUCTION

(HIMEDIA)
REAGENTS
Plate count agar, Potato dextrose agar.
SAMPLING OF AIR
⚫ Prepare plate count agar and Potato dextrose agar as per the manufacturer’s instruction (HI
MEDIA)
⚫ Pour the media into Petri plates in LAF and allow it to solidify.
⚫ Expose both the plates in the respective areas for 15 minutes to check for the aerobic microbial
count and yeast & mold count.
⚫ After 15 minutes, close the plate with a lid and incubate at 37°c ± 1°c for 48hrs for Aerobic plate
count and 72 hrs at 25°c ± 1°c for yeast and mould count
⚫ After the desired amount of incubation, check and count the colonies manually
RECORD OF RESULTS
Yeast and mould – cfu/15 minute’s exposure.
AMC – cfu/15 minutes exposure.
REFERENCE
IS 5403: 1999 (reaffirmed 2005).
IS 5402: 2012.
AIR MONITORING PLAN
Section Frequency Area

Mixing & Sieving area Once/Week
Whole Wheat Chapati
Chapathi making area Once/Week
PROCEDURE FOR SAMPLING PLAN Date of Release: 31/08/2022
PURPOSE
To check the microbiological quality of a product as per iD Fresh Foods standards.
SCOPE
This standard gives a methodology for sampling and microbiological analysis of particular
samples for Aerobic Plate Count (APC), Yeast and Mould Count (YMC), and Coliform
Count.
RESPONSIBILITY
Quality Control Microbiologist
INTRODUCTION
Microbiological testing is a crucial part of the quality assurance process because it anchors
the safety of the food product. Every product that passes through the plant must be attested to
have high standards that the consumers expect. It is important to conduct a series of
microbiological testing procedures on Chapati products to ensure that the final product meets
the required standards by passing all the stringent measures required for a satisfactory
product.
PRINCIPLE
The microbiological analysis is mainly carried out by standard plate count technique for
enumeration of viable count (Aerobic Plate Count, Yeast and Mould Count, Coliform Count).

• Autoclave for sterilizing microbiological media, diluents, and sampling bottles.
• Cool box
• 70%IPA
• Media bottle with autoclavable screw cap 500ml for preparing media.
PROCEDURE
• Depends on the purpose for which sampling is done and the type of the product being
sampled.
• First label the bottles with the date, time, area, and temperature, sampled by.
• For a sampling of swab or CIP water from tanks, nozzle wipes the nozzle with
70%IPA before sampling. Water runs for a few seconds before taking the sample.
Take some sample into the sterilized bottles swirl and drain repeat this. Take a sample
for analysis and tightly cap the bottle or swab. Microbiological samples should No
have preservatives. Hold the samples at a low temperature of 0-5 ̊C.
• The cool box used to store these samples should ensure. The temperature is
maintained.
• Transfer product to refrigerator as soon as possible.
• Microbiological Analysis should start within 24hrs after sampling. Record the sample
particular such as name of the sample, date, batch no, mfg date, and bbd. Clean the
exterior of the pouch or bottles with the sample packed with tissue paper and wipe it
off. Tissue paper/cotton soaked in 70%IPA to avoid external contamination. Allow
the traces of IPA to evaporate.
• Take the sample with aseptically transfer a representative portion of the sample into a
sterile test tube use it for further dilution.
• The parameter which needs to be tested for a particular sample, dilutions
• and results expression will be as per requirement.
PURPOSE
To check the microbiological quality of air as per iD Fresh Foods standards.
SCOPE
This standard gives methodology for sampling & microbiological analysis of air for enumeration of
aerobic plate count (APC) and yeast and mould count (YMC).
RESPONSIBILITY
Microbiologist
QA-Executive – To ensure the sampling plan is followed.
INTRODUCTION
Air quality inside the Chapati processing area influences the microbial quality of Chapati product.
Food products are highly susceptible to contamination by air borne microorganism. Microbial air
quality is critical point in the processing of Chapati products since air borne contamination reduce
shelf life and may serve as vehicle for transmitting spoilage. Air borne micro-organism in Chapati
manufacturing plant include mainly bacteria and yeast molds. The main sources of air borne organism
in the Chapati processing area includes the activity of factory personal, equipment, floor drain,
ventilation and air condition system, packaging material and water. Microbiological analysis of air
involves 3 main steps which are sampling, analysis and enumeration. Air sampling can be done by
sedimentation (settle plates). Air is generally analysed for aerobic plate count (APC) and yeast and
mould count (YMC). The APC and YMC are employed as of indicators of hygiene and sanitary
conditions of environment in production, processing and storage area.
PRINCIPLE
Sedimentation (settle plate technique used for determination of APC and YMC in air. In this
technique the selective solid agar medium in petri plate expose in process section / production area.
The petri plates are then incubated at a specified incubation temperature for specifies periods of time.
After the incubation period the colonies developed in each plate are counted and the count express in
CFU/ 15 minutes.

Autoclave - For wet sterilisation of microbiological media. At 121°c/15 PSI for 15 min.
Discarding Autoclave - For decontamination of biohazards in petri plate after taking count at
121°c/15 PSI for 30 min
Hot air oven - For dry sterilisation of glass petri plate, used at 165 ± 5°c for 3 hrs
(LAF) - For preparing aseptic media petri plates for microbiological analysis.
Incubator – For incubation of petri plate of TPC (37 ± 1°c) and YMC (25 ± 1°c)
Weighing balance – For the weighing of media
REAGENTS
Plate count agar, Potato dextrose agar.
MEDIA PREPARATION AND SAMPLING OF AIR

⚫ Prepare plate count agar and Potato dextrose agar as per the manufacturer’s instruction (HI
MEDIA)
⚫ Pour the media into petri plates in LAF and allow to solidify.
⚫ Expose both the plates in the respective areas for 15 minutes to check for the aerobic microbial
count and yeast & mold count.
⚫ After 15 minutes, close the plate with lid and incubate at 37°c ± 1°c for 48hrs for Aerobic plate
count and 72 hrs at 25°c ± 1°c for yeast and mould count
⚫ After the desired amount of incubation, check and count the colonies manually
RECORD OF RESULTS
Yeast and mould – cfu/15 minutes exposure.
APC – cfu/15 minutes exposure.
REFERENCE
IS 5403: 1999 (reaffirmed 2005).
IS 5402: 2012.
AIR MONITORING PLAN
Section AREA FREQUENCY
Sieving & Mixing area Once/Week

Whole Wheat Chapati
Chapati Making area Once/Week
CHEMICAL SAMPLING
TEST METHOD
SR SAMPLING PARAMETE SAMPLE
CRITER FREQUENCY OF SPECIFICATION
NO POINT R SIZE
IA SAMPLING
Whole
10 gm Moisture PH
1 Wheat Lab Weekly once Moisture; pH
1 gm 39±2 % 6.0-6.4
Chapati
PROCEDURE FOR HYGIENE Date of Release: 31/08/2022
Objective:
To provide guidelines & awareness about the personnel hygiene & Hygiene station entrance Facilities
procedure.
Scope:
All the employees of Arman Foodtech Pvt. Ltd. and contract labour, visitors, contractor, vendors, etc.,
whoever is entering the shop floor.
Responsibility:
Officer:
Must provide training regarding personnel hygiene. Also, verify that all the personnel working in
respective sections are following the personnel hygiene guidelines properly.
HOD:
Must ensure that all the personnel working in respective sections are following the personnel hygiene
guidelines properly.
BASIC GUIDELINES FOR PERSONAL HYGIENE:

All shop floor employees & contract labour must follow personal hygiene practices at all times.
This includes:
• Take bath daily.
• Washing hands and face when leaving the site and before eating, washing hands after
using the bathroom, before and after Taking Food, etc.
• Don’t bring & take any food items inside the manufacturing areas. It must be taken at
nominated lunchrooms/open dining areas;
• Uniforms must be clean, in good condition and laundered
• Glasses must be properly secured with cord.
• Keeping fingernails short and not biting nails;
• Person must have Clean Shave & Trim or short hair.
• Always Protect open cuts and wounds using dressings.
• Always wear good condition Safety shoes.
• Painted nails or using perfumed deodorants or other cosmetics are not allowed.
• Personnel must not bring any items inside the operational area which may pose a foreign
body contamination hazard.
• Visitors, contractor need to wear a disposable aprons, and safety shoe, i.e.to be provided
by the admin.
Procedure:
1. Remove all loose jewellery i.e., including rings, brooches, watches, earrings, necklaces
and visible piercings before entry to operational areas of the factory.
2. Wear the Disposable Hair cap &Face or Beard mask.

3. Wear the Disposable or Lindstrom Apron & hand gloves wherever required.
4. Apply a Hair remover roller to the clothes.
5. Clean the Shoe by applying through the shoe cleaning machine.
6. Deep the safety shoe into Hypo chloride footbath to sanitize the shoe sole.
7. Wash your hand thoroughly and lather vigorously using the soap solution for 15-30
seconds;
8. Rinse your hands under running water;
9. Do not touch taps with clean hands.
10. Expose the wet hand to the air dryer until fully dried.
11. Sanitize the dried hands by applying 70% IPA solution.
12. Upon leaving the hygiene station remove & throw the Disposable caps & apron to the
garbage. Disposables shall not be reused.
PROCEDURE FOR FUMIGATION & FOGGING Date of Release: 31/08/2022
PROCEDURE FOR FUMIGATION:
MATERIALS REQUIRED:
Formalin, KMnO4, ‘No Entry’ notices, cellophane tape, wet cloth, a container with tight
lids. Two persons for assistance.
SAFETY REQUIREMENT:
1. At least two persons (Out of which at least one should be well experienced) should be
involved in fumigation process.
2. Take along-with wet cloth to prevent against nasal irritation.
3. A ‘No Entry – area fumigated’ notice needs to be placed outside (at the entrance) the
fumigated area.
PRE-TREATMENT:
1. Clean all the equipment surfaces, floor area, walls, ceilings etc., thoroughly.
2. Remove all the scrap food material from the area.
3. Remove or close tightly food / products kept in the room/area prior to fumigation.
4. Ensure that all the ventilations, doors & windows are tightly closed.
PROCEDURE
1. Formalin is distributed in containers of small quantity (200-250 ml) and closed tightly
with the lid.
2. The containers are taken to the area to be fumigated and placed in room / area.
3. The lids are opened and sprinkle KMnO4 at the rate of approx. 25% of the quantity of
formalin taken in the container till it starts fuming.
4. After adding the KMnO4 in the formalin the person should come out immediately and
the area is sealed properly.
5. A notice indicating the time of starting the fumigation and opening should be placed.
6. After at least 3 hours of fumigation the doors are to be opened and the formaldehyde is
allowed to escape from the place.
7. The lids are replaced tightly on the formalin container and are brought back and stored
safely.
8. The details of the fumigation are maintained properly in a separate register for further
verification and references.
If case of EXPOSURE to the fumigant:
1) Move out of the fumigated area immediately.

2) Wash thoroughly the affected part.
3) Wash eyes thoroughly with plenty of water, if irritation occurs.
4) If irritation or discomfort persists, contact the doctor immediately.
POST-TREATMENT:
1) Do not enter the area alone, always go with a companion.
2) Switch on AC (if available), at least half an hour before entering the fumigated room.
3) Carry a wet cloth along, when entering the area. Use, if any irritation occurs.
4) In case of any irritation to any mucosal layer or any discomfort, come out
immediately.
5) Remove all the fumigants kept on the floor after at least min 3 hours of fumigation.
PROCEDURE FOR FOGGING:
FOGGING: Is a Process where an approved disinfectant is sprayed as a mist over the

exposed area and it is kept wet for 10-20 Min. to ensure effective disinfection. A fine
Mist is created by a well-designed Fogging Machine or Fumigator
MATERIALS REQUIRED:
Virosil, Fogger.
SAFETY REQUIREMENT:
1 At least two persons (Out of which at least one should be well experienced) should be
involved in FOGGING process.
2 Need to Wear all PPE (Mask, Hair net, Leather or Rubber gloved, goggle to prevent
against irritation.
3 No Person except the Fogging personnel present in the respective area till 10 Min after
Fogging completed.
FOGGING PROCEDURE
A) BEFORE FOGGING
1 Prepare Required Chemical Solution with the Desired concentration.

2 Remove all the scrap food material from the area.
3 Remove or close tightly food / products kept in the room/area prior to Fogging
4 Ensure that all the ventilations, doors, windows are Tightly closed and AHU must be
Switched Off.
B) FOGGING:
1. Prepare the Approved Fogging Solution with water as per the Recommended dosage
(5% concentration).
2. Carry out the Fogging out the activity by placing Air connection to the Fogger Machine
and spraying throughout the Respective area for 15-20 Min in such a way that it must
be uniformly distributed.
3. Allow the mist to Dry Naturally for 15 Min.
MEASURE FOR A SUCCESSFUL FOGGING OPERATION:

1. Identify the locations of placements of machine.
2. The Fogger Machine to be placed at the Identified Area.
3. In case of AC room place the machine below the duct pointing in direction of the Draft.
4. Seal All the openings and the gaps in window panels and exits.
5. On completion of Fogging, Isolate the area for 10-15 min.

6. To ensure that the Fogging is complete, Check the Sponge filter, when the filter is wet,
it indicates that the entire area is Fogged.
7. The details of the fumigation are maintained properly in a separate register for further
verification and references.
If case of EXPOSURE to the Fogging Chemical:

1. Move out of the Fogging area immediately.
2. Wash thoroughly the affected part.
3. Wash eyes thoroughly with plenty of water, if irritation occurs.
4. If irritation or discomfort persists, contact doctor immediately.
POST TREATMENT:
1. Clean The exposed Surfaces thoroughly with water.
2. Now the area is ready to use.
Corrective Action: Whenever the Air Microbiology counts of Yeast and Mold Shows
150 cfu/M3 and the standard plate count shows 200 cfu/m3, Production Must be
temporarily stopped to do the fogging of the area.
Fogging Fumigation
Area Time Time
Frequency Frequency
At the end of production/
Sieving & Anytime Preferably at the start
Twice/Week Twice/Month When there is no
Mixing area or end of production
Production
At the end of production/
Chapathi Anytime Preferably at the start
Twice/Week Twice/Month When there is no
making area or end of production
Production
WHOLE WHEAT CHAPATI SAMPLING PLAN Date of Release: 31/08/2022
A. WHOLE WHEAT CHAPATI SAMPLING PLAN
SR NO OF
PRODUCT TYPE VARIETY QUANTITY FREQUENCY
NO SAMPLE
Whole Wheat
1 Whole Wheat Chapati 2 2 EVERY BATCH
Chapati
SR. NO. DESCRIPITON SAMPLE LOCATION

1 MICROBIOLOGICAL ANALYSIS ONLINE SAMPLE TO ANEKAL
2 CONTROL SAMPLE COLD ROOM - SHELF LIFE SECTION
3 VISUAL INSPECTION ONLINE
PROCEDURE FOR SENSORY EVALUATION Date of Release: 31/08/2022
Sensory Evaluation of Chapati (Test Plan-01):
The sample should be warmed to 30±2˚C for sensory evaluation of taste & odour. Evaluation will be
conducted minimum two days in a week. Following samples will be included in the evaluation.
1. Chapati Samples : 2 samples
2. Stored samples of Chapati kept for shelf life : 1 sample
3. Complaint sample /Market (Competitor) samples : As and when received
Sensory Evaluation of Chapati Products (Test Plan-02)

Evaluation will be conducted minimum two days in a week. Following samples will be included in the
evaluation.
1. Finished Chapati product : 3 Samples
2. Stored samples of Chapati Products kept for shelf life : 2 Samples
3. Complaint sample / Market (competitor) samples : As and when received
Recommended temperature requirement of Chapati products for sensory evaluation:

Sr. No. Product Temperature (˚C)
1. Whole Wheat Chapati
Note: The number of samples and frequency and frequency may be decided (increase or decrease)
depending upon the product availability and shelf life.
REFERENCES:
Evaluation card for paired comparison test (simple difference)
Evaluation card for threshold test
Inspection and Test plan for sensory evaluation of Chapati
Evaluation card for numerical scoring test for overall quality of Chapati
PROCEDURE FOR CHAPATI BATCH CODE PRINTING Date of Release: 31/08/2022
PURPOSE: Define and document the operational procedures of Whole wheat chapati Batch
coding and labelling.
RESPONSIBILITIES: Manager Production is responsible for correct batch coding and labelling
on FG, QA TPM and QA personnel ID are in charge for verification.
SCOPE: The procedure applies to all packing labels for Whole wheat chapati
PROCEDURE:
1. Ensure that the Printing machine and the printing conveyor is cleaned before start of
labelling/printing.
2. Before printing, printing personnel should get the Batch code, MRP and Use by details
according to the products by QA or Production incharge. See below how to define the
batch coding and Use by Date.
3. Switch on the printing machine.
4. Feed the approved data of Batch Number, Use by date, MRP etc. in the printing machine
before printing.
5. Take a trial of printing the details on the pouch and get confirmation from QA or Production
in charge. Printing matter shall be legible,in the described format only and within the space
provided, No overlapping on the pouch printed matter, No cutting of fonts. QA needs to
ensure these before giving confirmation.
6. Once QA or Production incharge gives the confirmation, start feeding the pouches which
are needed to be printed.
7. Handover sample printed pouch to QA on each time of printing.
8. Only trained and authorized persons are allowed to handle the printing machine.
Batch code will be defined as per below format:
Following details should be printed on Each and every pkt of Chapati FG
1. Batch code
2. Use By Date
3. MRP . Max. Retail Price
Printing Format shall be in the below described format only :

Whole wheat Chapati
MRP : 75/-
Use By Date: Packing date + 6 Days
Batch Code : Plant code/ Month code/Manufacturing date / Batch no./ Shift of Manufacturing
If the date of manufacturing is 25th Sept.2022 and manufacturing(Mixing) of 1st batch is done in
first shift then the batch code will be defined as :
Date 25.09.2022 Code BI25B01A
A I 25 B01 A
Month Date of mixing Batch

Plant Shift
and processing No.
Arman
Sept. 1st to 31st Batch No.1 - B01 A or B
Foodtech
Jan. -A Batch no.5 - B05 6 am to 6 Pm - A
Dec.-J 6 Pm to 6 Am - B
UBD : Use By Date Determination :

Whole wheat
Details
Chapati
Use By Date 6 Days (P+6)
MRP Rs. 75/-
Storage <5°C
From the Date

UBD
and Time of
Calculation
packing
*If the packing of first batch of Whole wheat chapati started at 2.00 PM(Noon) on 24.09.2022
then the UBD will be Packing date + 6 Days i.e. 30.09.2021 and if the packing date is 02.00
AM on 01.10.2021 (30th sept. Midnight) then the UBD will be 07.10.2022 .
RECORDS:
1. Date Coding Verification Register

2. Chapati Packing Checklist
CORRECTIVE ACTIONS:
1. In case of misprinting, printing personnel is responsible to remove all the label on
the pouches by using thinner. While using thinner ensure thinner should not go inside the
pouches.
2. All the Packets of Chapati needs to be cross verify during sorting before dispatch,
all the pkts which are having any issue related to printing I.e. Misprinting, No printing,
Wrong batch code, wrong UBD , Overlapping on pkt printed matter or incorrect format etc
should be sorted out and kept separately and follow point 1.
Chapter 12 Master Cleaning & Sanitization
MASTER CLEANING AND SANITATION SCHEDULE - ARMAN

CLEANING AND SANITATION BY CONTACT
AREA AND NAME OF THE CLEANING
SL NO. FREQUENCY TIME IN
EQUIPMENT METHOD DETERGENT CONC.(%) SANITIZER CONC.(%) METHOD
MINS.
A GROUND FLOOR
OFFICE ROOM 1 15
1 Floor Manual Daily LIZA 0.50% Santonil 0.30% Mopping
2 Windows and mesh Manual weekly once NA NA Santonil 0.30% Mopping
4 Cob web C.I.P weekly once NA NA NA 0.30% NA
5 Slab Manual Daily NA NA Santonil 0.30% Mopping
6 Racks Manual Daily NA NA Santonil 0.30% Mopping
B OFFICE ROOM 2 15
1 Window Manual weekly once NA NA Santonil 0.30% Mopping
2 Mesh Manual weekly once NA NA Santonil 0.30% Mopping
4 Slab Manual Daily NA NA Santonil 0.30% Mopping
5 Rack Manual Daily NA NA Santonil 0.30% Mopping
6 cob web C.I.P weekly once NA NA Santonil 0.30% NA
C COLD ROOM 15
2 Mesh and windows Manual weekly once NA NA Santonil 0.30% Mopping
3 cob web Manual weekly once NA NA NA NA
4 Control sample rack C.I.P Daily NA NA NA Mopping
5 Freezer C.I.P Daily NA NA NA NA
D RM/PM STORE 15
1 Windows and mesh Manual weekly once LIZA 0.50% Santonil 0.30% Mopping
2 cob web C.I.P weekly once NA NA NA NA
3 weighing machine C.I.P Daily NA NA Santonil 0.30% Mopping
4 Rodent box C.I.P weekly once NA NA NA NA

5 Trolly Manual Daily NA NA Santonil 0.30% Mopping
E RECEPTION AREA 15
1 Tables Manual Daily NA NA Santonil 0.30% Mopping
2 Racks Manual Daily NA NA Santonil 0.30% Mopping
3 windows and mesh Manual weekly once NA NA Santonil 0.30% Mopping
5 In front of entrance Manual Daily LIZA 0.50% Santonil 0.30% Mopping
F HYGIENE STATION 15
1 Hand wash basin Manual Daily LIZA 0.50% Santonil 0.30% Mopping
2 Hand dryer Manual Daily LIZA 0.50% Santonil 0.30% Mopping
4 Detergent and IPA dispenser Manual Daily LIZA 0.50% Santonil 0.30% Mopping
5 Foot wear stand Manual Daily LIZA 0.50% Santonil 0.30% Mopping
G FIRST FLOOR: PAROTA SECTION

PRODUCTION AREA 15
2 Water tank Manual Daily LIZA 0.50% Santonil 0.30% Mopping
4 cob web C.I.P weekly once NA NA NA NA
5 Packing area Manual Daily LIZA 0.50% Santonil 0.30% Mopping
6 Raw materials mixing machine Manual Daily LIZA 0.50% Santonil 0.30% Mopping
7 Tawa Manual Daily LIZA 0.50% NA
8 Dressing room Manual Daily NA NA Santonil 0.30% Mopping
9 Corridar Manual Daily LIZA 0.50% Santonil 0.30% Mopping
10 Trays Manual Daily NA NA Santonil 0.30% Mopping
H HYGIENE STATION 15
1 Hand wash basin Manual DAILY LIZA 0.50% Santonil 0.30% Mopping
2 Hand dryer Manual DAILY LIZA 0.50% Santonil 0.30% Mopping
3 Detergent and IPA dispenser Manual DAILY LIZA 0.50% Santonil 0.30% Mopping
4 Footwear stand Manual DAILY LIZA 0.50% Santonil 0.30% Mopping
I SECOND FLOOR: CHAPATI SECTION

PRODUCTION AREA 15
1 Raw materials mixing machine Manual Daily LIZA 0.50% Santonil 0.30% Mopping
2 weighing machine Manual Daily LIZA 0.50% Santonil 0.30% Mopping
3 floor Manual Daily LIZA 0.50% Santonil 0.30% Mopping
5 chapati making machine Manual Daily NA NA Santonil 0.30% Mopping
6 Packing area Manual Daily LIZA 0.50% Santonil 0.30% Mopping
7 Cob web C.I.P weekly once NA NA NA 0.30% NA
8 Dressing room Manual Daily NA NA Santonil 0.30% Mopping
9 corridar Manual Daily LIZA 0.50% Santonil 0.30% Mopping
J HYGIENIC STATION – SECOND FLOOR 15

1 Hand wash basin Manual Daily LIZA 0.50% Santonil 0.30% Mopping
2 Hand dryer Manual Daily LIZA 0.50% Santonil 0.30% Mopping
3 Detergent and IPA dispenser Manual Daily LIZA 0.50% Santonil 0.30% Mopping
4 Foot wear stand Manual Daily LIZA 0.50% Santonil 0.30% Mopping

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Table of Contents

Chapter No. Title Page No.

5. Process flow & Process Mapping

6. PM Specs (Verification & Movements)

9. Dispatch & Transportation

10. NPD trials & lists

11. Document Lists

13. Master cleaning & sanitation schedule

1. Product name : Whole wheat chapati

1. CHAPATHI – RECIPE DETAILS

Wheat atta (Vivek Agro) 25 kg

Wheat atta (Annapurna) 25 kg

Water 33.5 litres

Total Wt (approx.) kg 88.55 Kg

1. Wet dough ball weight : 53-55grams

2. Top Plate Temperature : 180 degree celsius

3. Bottom Plate Temperature : 170 degree Celsius

5. Cooling time : 1.5-2 min

6. After cooking chapati weight : 50-52 grams

Biological, Chemicals and Physical Characteristics:

Moisture content : 10-13% by weight (when determined by heating

Total Ash : NMT 2.0% on dry weight basis

Gluten (on dry basis)% by mass : 8-9.5%

Gluten (on wet basis)% by mass : 28-30%

Water absorption : 64-68%

Granularity : Zero % retention on mesh BSS#60, 95%

Yield per kg : 20 pieces

Metal contaminants : As per FSSAI requirement

Crop contaminants : As per FSSAI requirement

Pesticide residues: As per FSSAI requirement

Composition and Origin:

Appearance and Consistency : Dark Creamish flour

Yeast &Moulds : 500

: Atta flavoured, salty noted in aftertaste. With good

Packing and storage Information

Biological, Chemicals and Physical Characteristics:

Matter insoluble in water : NMT 1.0% by weight on dry basis

Iodine content at:

Composition and Origin:

Appearance and Consistency : White colour, free flowing powder

Flavour : Characteristic flavour

Packing and storage Information

Storage condition : Ambient condition

RM condition : Free from any insect live or dead.

Biological, Chemicals and Physical Characteristics:

Moisture content : NMT 0.5% by weight

Sucrose : Not less than 99.5% by weight on dry basis

Composition and Origin:

Appearance and Consistency : White colour, Crystalline structure

Flavour : Characteristic flavour

Packing and storage Information

Storage condition : Ambient condition

RM condition : Free from any insect live or dead.

4. SUNFLOWER OIL SPECIFICATIONS

Biological, Chemicals and Physical Characteristics:

Free fatty acid : NMT 0.25%

Refractive Index at 40°C : 1.4640- 1.4800

Butyro-refractometer reading at 40°C : 57.1-65

Flash point (pensky marten closed method): NLT 250°C