GEL SYSTEMS LTD Version: 25

Hazard Analysis Document Ref: GSLF/13

Site: Riccall Airfield Ind Est, North Yorkshire YO8 5LD Issued by: A.HARLAND
Date: 26th June 2024 Signed:

HAZARD ANALYSIS - RISK TO FOOD SAFETY

L = Liklihood of Occurrence S = Severity of Outcome R = RISK LEVEL
3 = HIGH - Likely to happen unless controlled 3 = HIGH - Death or serious injury 1-3 = LOW
2 = MEDIUM - may happen unless controlled 2 = MEDIUM - minor injury and customer complaint 4-6 = MEDIUM
1 = LOW - unlikely to happen 1 = LOW - customer complaint 7-9 = SUBSTANTIAL

HAZARD ANALYSIS
Process Stage Step No. Hazards Type L S R CCP decision CCP CP Preventative Action Validation Critical Limit Responsibility

Raw ingredients/packaging in 1 Presence of foreign objects Physical 1 3 3 YNYY Yes Use of approved suppliers. Material Handler
from supplier Supplier meets GSL approval QC Manager.
Presence of heavy metals Chemical 1 3 3 YNN Use of approved suppliers. criteria QC Manager
from supplier
Use of approved suppliers.
Microbiological contamination due Keep powder dry to prevent
to growth within raw material. Microbiological 1 3 3 YNN microbiological growth. QC Manager

Minimal incidents of damaged

bags within 12 month period.
Pallet stored in warehouse 2 Physical contamination due to Physical 1 1 1 YNN Yes Careful handling by trained Production Operatives / Material Handler.
damaging goods staff.
Physical contamination due to Careful handling by trained
Ingredients/Packaging picked (CCP1) 3 damaging goods. Physical 1 1 1 YNN Yes staff. Material Handler

Picking from recipe and

blending check and bag Correct recipe
Safety and quality issue due to count. Second check See FD/25 provided, correct
picking wrong raw material or completed by another raw materials
wrong quantity of raw material. Chemical 1 3 3 YNYN Yes production operative. picked Production Operatives

Careful handling by trained

Microbiological contamination due staff. Keep powder dry to
to contamination and growth within prevent microbiological
raw material. Microbiological 1 3 3 YNN Yes growth. QC Manager

Minimal incidents of damaged

bags within 12 month period.
Ingredients/packaging transferred 4 Physical contamination due to Physical 1 1 1 YNN Yes Careful handling by trained Production Operatives.
to production area damaging goods staff.

Products transferred to Whittakers for outsourced Minimal incidents of damaged

Physical contamination due to Careful handling by trained
processing bags within 12 month period.
4A damaging goods Physical 1 1 1 YNN Yes staff. Warehouse Operatives
Bag labelling 5 Chemical 2 3 6 YNN Yes Follow label control process Production Operatives

SOP007 states only current

labels are available to use,
Chemical inclusion due to Monitor compliance to labels issued by authorised
incorrect information on label process personnel Production/QC Manager.
Careful handling by trained
Machine charge 6 Packaging contamination Physical 1 1 1 YNN Yes staff, Production Operatives.
Magnet and sieve on line

Training against SOP014.

Sieve would remove any
Careful handling by trained packaging accidently tipped
Microbiological contamination due staff. Keep powder dry to in. No water in area and
to contamination and growth within prevent microbiological product has low water
raw material. Microbiological 1 3 3 YNN growth. activity. QC Manager
Magnet 7 Metal contamination passing Physical 1 3 3 YNYY Yes Regular cleaning Production Operatives.

No non-conformances relating
magnet Sieving downline to metallic contamination.
Product blended 8 Contamination from blender Physical 1 1 1 YNN Yes PPM Production Operatives.
parts Sieving downline PPM schedule maintained.
Training against SOP014.
Careful handling by trained Sieve would remove any
Microbiological contamination due staff. Keep powder dry to blender parts. No water in
to contamination and growth within prevent microbiological area and product has low
raw material. Microbiological 1 3 3 YNN growth. water activity. QC Manager
Removal of raw material packaging waste to baler then Contamination from raw material Careful handling by trained
skip, removal of sieve reject waste for QC inspection waste packaging or sieve reject staff. Timely removal of waste Waste removal follows flow
and then to skip 9 waste Physical 1 3 3 YNN Yes from production area. stated in GSLD/04 Site Plan. Production Operatives.
Correct sieve size, in tact,
Discharge through sieve 10 Contamination passing sieve Physical 1 3 3 YY Yes and undamaged Sieve correct Production Operatives.
(CCP2) due to damage (incl. sieve size (as per
parts) See FD/25 blend sheet -
Careful handling by trained max 2mm),
Microbiological contamination due staff. Keep powder dry to intact and
to contamination and growth within prevent microbiological undamaged
raw material. Microbiological 1 3 3 YNN growth. QC Manager
Products bagged and weighed 11 Physical 1 2 2 YNN Yes Production Operatives.

Glass and hard plastics

audits, scoop integrity
Contamination of product whilst checks, hairnets and beard
bag is open with hard plastic snoods worn, seal bags in
(scoop), or from operative (hair) timely manner Staff training against SOP005
Topping up bag open for a
short period of time and
Bag topped up 12 Contamination of product Physical 1 3 3 YNN Yes covered when not in use. Production Operatives.
from topping up bag
Careful handling by trained Staff training against SOP005
Microbiological contamination due staff. Keep powder dry to and no test results showing
to contamination and growth within prevent microbiological failed microbiological results
raw material. Microbiological 1 3 3 YNN growth. within 12 month period. QC Manager
Bags sealed 13 Contamination of product. Physical 1 2 2 YNN Yes Seal bags without delay after Production Operatives.
while bag is open topping up.
Careful handling by trained Staff training against SOP005
Microbiological contamination due staff. Extremely unlikely as and no test results showing
to contamination and growth within dry powder does not support failed microbiological results
raw material. Microbiological 1 3 3 YNN microbiological growth. within 12 month period. QC Manager
Bags palletised 21 Damage to packaging Physical 2 2 4 YNN Yes Staff training. Production Operatives.
Staff training against
from pallet Safe operating procedures. Production Operatives.
SOP012. Pallets are checked
Use of good quality pallets Directors.
before entering production.
and bags.
Pallets wrapped 22 Damage to packaging. Physical 1 1 1 YNN Yes Production Operatives.

Standard operating Staff trained against

Heat damage to product. procedures. SOP021.
Pallets labelled 23 Chemical (vitamin) inclusion due Chemical 2 3 6 YNN Yes Follow label control process SOP007 states only current Production Operatives
to incorrect information on label labels are available to use,
Monitor compliance to labels issued by authorised
process personnel Production / QC Manager
Stored in warehouse 24 Physical contamination due to Physical 1 1 1 YNN Yes Careful handling by trained Production Operatives.
staff. Goods out pallets stored
within dedicated areas and no
damaging goods more than two pallets high.
Whittakers have designated
nut processing room and
storage area. Outsourced
processing takes place away
from nut room and storage No incidents of contaminated
Introduction of nuts as Whittakers area, in line with Whittakers material being returned to
Products returned from Whittakers 24A is not a nut free site Allergenic 2 3 6 YNN Yes allergen control procedures. GSL in 12 month period. Warehouse Operatives / QCT
Despatch 25 Physical contamination due to Physical 1 1 1 YNN Yes Careful handling by trained Production Operatives.
staff.
Staff training against
damaging goods SOP012.
GV4 specific
Process Stage Step No. Hazards Type L S R CCP decision CCP CP Preventative Action Validation Critical Limit Responsibility
Conveyor to filling machine 14 No sig. hazards Yes
hopper
Store off the floor and handle Dust extraction in place and
Print film and label 15 Dirt and dust on film Physical 2 1 2 YNN Yes with care. maintained. Manager / Controller.

Machine set up and operator

Form and bottom seal 16 Ingress due to poor seal Physical 2 2 4 YNN Yes vigilance. Manager / Controller.
No evidence of poor seals
leading to physical
contamination.

Full bags 17 Ingress of physical contaminants. Physical 1 2 2 YNN Yes Product enclosed within Manager / Controller.

Physical contamination very

unlikely due to machine
equipment design.
Machine set up and operator
Top Seal and cut 18 Ingress due to poor seal Physical 2 2 4 YNN Yes vigilance. Manager / Controller.
No evidence of poor seals
leading to physical
contamination.
Must reject
2.5mm Fe,
Metal detection (where customer specifies Metal passing due to faulty Metal detector correctly 3.0mm Fe and
requirement) 19 detector. Physical 1 3 3 NN Yes calibrated. 3.0mm SS Manager / Controller.

Pass each test

piece through
the detector
within product
that has already
passed the
detector
successfully.
Each piece must
trigger the
detector stop
mechanism first
Annual calibration and time. Check to
maintenance and staff trained be performed at
against FP/41. the start of a
run, end of run.

If detector fails
the calibration
check, stop
production and
re-calibrate the
detector.
Isolate all
product made
since the last
good check and
re-detect
through the
detector when
functioning
properly.

Check Weighing 20 No sig. hazards