Page | 1 A-033-A UMPC Bldg., Poblacion, La Trinidad, Benguet Email: bamfoodopc@gmail.com STANDARD OPERATING PROCEDURES MANUAL Quality • Wholesomeness • Food Safety • Traceability 2026 EDITION Document Control Field Details Document Title BAM Food OPC SOP Manual Document No. BAM-SOP-MAN-001 Version 2026.2 - Lean Micro-Business Edition Management Owner and Manager only Prepared/Approved by Owner
Page | 2 Table of Contents Page How to Use this Manual . . . . . . . 3 1. Essential GMP Rules for Everyday Production Day . . 3 1.1. Personnel Hygiene . . . . . . 3 1.2. Area, Zoning and Housekeeping . . . . 4 1.3. Cleaning and Equipment . . . . . 4 2. Materials, Receiving and Storage . . . . . 4 3. Lean Production and Batch Control . . . . . 5 4. Product Specific Control Guides . . . . . 6 4.1. Strawberry Jam . . . . . . . 6 4.2. Lemon Tea . . . . . . . 8 4.3. Dried Santol . . . . . . . 10 4.4. Dried Strawberry . . . . . . 12 4.5. Dried Vegetable Pear/Chayote . . . . 16 5. Packaging, Product Release and Storage . . . . 19 6. Problems, Returns, Complaints and Recall . . . . 19 7. Inventory and Traceability . . . . . . 20 8. Confidentiality and Photography Control . . . . 20 9. Minimum Records – Lean System . . . . . 21 Appendices: Samples of Forms Form-01 Batch Production and Release Records . . . 23 Form-02 Incident/ Hold/ Complaint/ Recall Records . . 24 Form-03 Stock Movement and Sales Record . . . 25 Form-04 Monthly GMP/ Facility Check . . . . 25 Form-05 Confidentiality and Non-photography Undertaking . 26
Page | 3 How to Use This Manual This manual is the everyday guide for BAM Food OPC processing staff, part-time workers and OJTs. It explains what to do before, during and after processing in simple steps. Follow the instructions in order. If something is unclear, different from the guide, or appears unsafe, STOP and ask the Manager or Owner before continuing. Simple rule: DO IT RIGHT - CHECK IT - RECORD ONLY WHAT MATTERS. Never guess an ingredient, quantity, processing time, product identity or corrective action. • Owner: final approval for formulations, major changes, recalls and serious corrective actions. • Manager: daily supervision, batch review, sanitation check, receiving, inventory and routine product release. • Assigned staff/OJTs: follow the approved process, hygiene rules and batch instructions; report problems immediately. • When the Owner or Manager personally performs a task, a separate second- person signature is not required unless a specific legal, customer or validated- process requirement requires it. • Do not change formulations, coded ingredients, processing conditions, packaging or labels without Owner authorization. 1. Essential GMP Rules for Every Production Day These rules apply every time food is processed. GMP means Good Manufacturing Practices - simple habits that keep dirt, germs, chemicals, pests and foreign objects away from food. 1.1 Personnel Hygiene Why this matters: People can transfer germs, hair, dirt and other contaminants to food. Clean hands, clean clothing and good health are the first protection. • Do not handle food when suffering from vomiting, diarrhea, jaundice, fever with sore throat, infected wounds or another condition that may contaminate food. Report to the Manager or Owner. • Remove jewelry and loose personal items. Wear clean laboratory gown/apron (follow scheduled uniform), hair restraint and appropriate closed footwear. • Wash hands with soap and potable running water for at least 20 seconds before food handling and after contamination, toilet use, breaks, waste handling, coughing/sneezing or task changes.
Page | 4 • No eating, smoking, chewing gum, or betel nuts or open drinks in processing and storage areas. Gloves do not replace handwashing. 1.2 Area, Zoning and Housekeeping Why this matters: Raw materials, dirty washing activities, chemicals and waste can contaminate clean food or packaging if they are mixed together. • Keep wet washing/preparation activities separated from dry processing/packaging as far as practical. • Keep raw materials, work-in-process, packaging, finished products, chemicals, waste and returned/rejected products separated and clearly identified. • Keep food and packaging off the floor and protected from splash, dust, pests and condensation. • Remove waste after processing and keep work areas orderly. 1.3 Cleaning and Equipment Goal: Anything that touches food must be clean, in good condition and free from old food, detergent residue, rust, loose parts or other contamination before production starts. 1. Remove product and loose debris. 2. Disassemble removable food-contact parts where applicable. 3. Wash with the liquid detergent and potable water. 4. Rinse thoroughly. 5. Air-dry/drain-dry and inspect before use. 6. After production, clean equipment used that day. Record only an abnormal condition, repair, breakdown or missed cleaning on the Batch Production Record or Deviation/Incident Record. Routine equipment cleaning does not require a separate daily equipment log when completion is confirmed on the Batch Production Record/Daily GMP Check. Preventive maintenance and calibration are recorded only when performed or when a problem occurs. 2. Materials, Receiving and Storage Goal: Start with good materials. A good process cannot fully correct moldy fruit, contaminated ingredients, damaged packaging or wrongly identified additives. • Buy ingredients and packaging from known/acceptable suppliers. Keep delivery receipts, invoices or supplier documents as the normal receiving evidence.
Page | 5 • On receipt, check identity, condition, expiry where applicable, pest/mold damage, packaging integrity and jar/lid defects. Record only rejected, held or unusual deliveries in the Deviation/Incident Record. • Use potable water for food preparation, produce washing and food-contact rinsing. • Label opened ingredients with identity and, where useful, date opened/lot. Use FIFO/FEFO. • Keep chemicals separately from food and packaging. • Internal codes protect formulation confidentiality but do not replace the full ingredient name on supplier, regulatory or controlled formulation records. Internal Code Ingredient C585 Citric acid G230 Guar gum S370 Sorbate - exact chemical identity per approved supplier label A240 Ascorbic acid M245 Potassium Metabisulfite 3. Lean Production and Batch Control A batch is one group of product made using the same formulation during one production run. The batch/lot code is the product's tracking identity. If a problem is reported later, this code helps BAM identify when and how the product was made. For routine commercial production, the main food-safety/quality record is FORM- 01 Batch Production & Release Record. It combines ingredient verification, pre- operation checks, process observations, water-bath/dehydration information, packaging checks, yield, deviations and Manager release. Separate logs are used only when a real event requires them. 1. Before production, confirm the correct product guide/formula, ingredients, packaging and labels. 2. Assign a batch/lot code and record the production date. 3. Check the work area before bringing ingredients into production. Tables, utensils and equipment must look and smell clean, with no old food or detergent residue. Place an empty container on the scale if needed, tare/zero it, and confirm the display returns to zero before weighing. 4. Weigh ingredients one at a time according to the approved product guide. Read the ingredient name before weighing. For coded ingredients, read both the code and full name - for example, 'C585 - Citric acid.' Compare the
Page | 6 required amount with the scale reading before adding it. If unsure, do not add it. 5. Keep the product guide beside the work area where it can be read without contaminating food. Follow each step in order and do not skip ahead. Record the batch code, important processing time/duration, water-bath or drying information, problems and release decision on FORM-01. 6. Do not substitute or change ingredient quantities without Owner authorization. 7. After processing, inspect finished containers one by one or in manageable groups. Remove any broken, leaking, poorly closed or visibly contaminated package. Confirm the correct product/variant label and readable batch code before release. 8. The Manager reviews FORM-01 and releases acceptable product. The Owner decides unusual, serious or safety-related cases. 4. Product-Specific Control Guides IMPORTANT FOR PROCESSING STAFF: Read the guide for the product you are making BEFORE starting. Prepare all ingredients and equipment first. Follow the steps in the exact order shown. STOP means do not continue the questionable step. HOLD means keep the affected product separate and do not sell or release it until the Manager or Owner decides what to do. These guides are the primary day-to-day instructions for processing staff. Follow the approved formulation and sequence exactly. The 'Control Points' explain what staff must watch to protect quality, wholesomeness and safety. 4.1 Strawberry Jam Before starting: Read the full Strawberry Jam guide. Confirm that strawberries, sugar, oil, C585, G230, S370 and A240 are available and correctly identified. Prepare the scales, cooking vessel, stirring utensil, clean jars/lids, water-bath canner and FORM-01. Do not start if an ingredient is missing or its identity is uncertain. Approved Formulation Quantity 1st Mixture – Strawberry 5 kg 1st Mixture – Sugar 2.5 kg 1st Mixture – Oil 2 tbsp 2nd Mixture - C585 15 g 2nd Mixture – Sugar 0.5 kg 2nd Mixture - G230 80 g 2nd Mixture - S370 12 g 2nd Mixture - A240 15 g
Page | 7 Raw Material and Preparation What 'accepted strawberries' means: use fruit suitable for processing and free from visible mold, rot, insects, objectionable smell and foreign materials. Do not simply mix spoiled fruit into the batch. • Use accepted strawberries. Remove moldy, spoiled, pest-damaged or foreign material. • Remove calyx using a clean stainless utensil, then wash with potable water and drain. • Use clean jars, lids, cooking utensils and food-contact equipment. Processing Steps 1. Combine the 1st mixture. Cook over very low heat while continuously and carefully stirring to avoid scorching and excessive mashing. 2. When the sugar dissolves and the mixture becomes watery, increase heat to medium-high and continue until boiling starts. 3. Mix the 2nd mixture thoroughly before addition. 4. Add the 2nd mixture gradually while continuously stirring to prevent lumps and uneven distribution of the coded ingredients. 5. Continue cooking with careful stirring until bubbles disappear, approximately 20 minutes under the current BAM process instruction. 6. Pack immediately into clean/washed glass jars. Keep the jar rim clean, apply the cover and seal. 7. Process sealed jars in the water-bath canner for 20 minutes under the current BAM process instruction. 8. Remove immediately and allow to air-dry/cool in a clean protected area. Inspect jars and closures before labeling/release. Strawberry Jam - Key Control Points What to Control Staff Guidance / Acceptable Condition Action if Not Acceptable Raw strawberries Sound, suitable ripe fruit; no mold/spoilage Remove/reject affected fruit. Ingredient identity & weight Exact approved ingredients and quantities; verify C585, G230, S370, A240 STOP. Do not guess or substitute. Ask Manager. Cooking Continuous careful stirring; no scorching; follow heat sequence Reduce/adjust heat; segregate seriously scorched batch for Manager decision.
Page | 8 2nd mixture addition Premixed and added gradually; no visible gum lumps Continue controlled mixing; report significant lumping/non-uniformity. Jar condition Clean, intact jars/lids; clean rim; properly closed Do not use defective jars/lids. Water bath 20 min current BAM instruction; record actual start/end or duration on FORM-01 If interrupted/short, HOLD batch for Manager/Owner decision. Finished product No leakage, broken jar, obvious seal defect, mold or foreign material HOLD affected units/batch. 4.2 Lemon Tea Before starting: Confirm which Lemon Tea variant will be made - Turmeric, Malunggay, Roselle, Ginger or Passion Fruit. Prepare only the ingredients for that variant. Confirm lemon, sugar, approved syrup, C585 and G230 before weighing. Prepare the slicer, cooking vessel, stirring utensil, clean jars/lids, water-bath canner and FORM-01. Approved Base Formulation Quantity 1st Mixture – Lemon 10 kg 1st Mixture – Sugar 5.5 kg 1st Mixture – Syrup 6.5 kg 1st Mixture - C585 20 g 2nd Mixture – Sugar 1 kg 2nd Mixture - G230 180 g Variant Addition to 1st Mixture Turmeric 30 g turmeric Malunggay 50 g malunggay Roselle 130 g roselle Ginger 50 g ginger + 10 g turmeric Passion Fruit 2,500g Use only the approved syrup specified in BAM Food OPC's controlled Master Formula/supplier specification. Raw Material and Preparation What to look for: lemons should be suitable for processing and free from visible mold, rot, objectionable smell and serious damage. Remove seeds and unwanted fibrous center portions because these can affect eating quality and consistency. • Use accepted lemons; remove spoiled, moldy or damaged fruit.
Page | 9 • Wash lemons thoroughly using the approved BAM preparation method and potable-water rinse. Remove seeds and unwanted fibrous center portions, then slice with a clean designated slicer/blade. • Confirm the correct variant before weighing and keep variant ingredients clearly identified. • Use clean jars, lids, cooking utensils and food-contact equipment. Processing Steps 1. Combine all ingredients of the 1st mixture, including the ingredient(s) for the selected variant. 2. Cook over medium-high heat while slowly stirring to avoid scorching. 3. When the 1st mixture starts to boil, gradually add the properly mixed 2nd mixture while continuously stirring to avoid lumps. 4. Continue cooking with careful stirring until bubbles disappear, approximately 10-15 minutes under the current BAM process instruction. 5. Pack immediately into clean/washed glass jars. Keep rims clean, install covers and seal. 6. Process sealed jars in the water-bath canner for 10 minutes. 7. Remove immediately and allow to air-dry/cool in a clean protected area. Inspect jars and closures before labeling/release. Lemon Tea - Key Control Points What to Control Staff Guidance / Acceptable Condition Action if Not Acceptable Lemons Sound fruit; seeds/unwanted fibrous portions removed; clean preparation Remove defects; re- clean/re-sort before cooking. Correct variant Variant and addition match production plan STOP if wrong ingredient/variant is staged. Ingredient identity & weight Exact approved quantities; verify C585 and G230 STOP. Do not guess or substitute. Ask Manager. Cooking Medium-high heat; slow/careful stirring; no scorching Adjust heat/stirring; HOLD seriously scorched batch. 2nd mixture addition Premixed and gradually added; no visible gum lumps Continue controlled mixing; report significant lumping. Jar/closure Clean, intact, clean rim, properly closed Reject defective jars/lids.
Page | 10 Water bath 10 min.; record actual start/end or duration on FORM-01 If interrupted/short, HOLD batch. Finished product Correct variant, acceptable appearance, no leakage/seal defect/foreign material HOLD affected units/batch. 4.3 Dried Santol Before starting: Read the full Dried Santol guide. Confirm that santol, sugar, citric acid and metabisulfite are available and correctly identified. Prepare the steamer, clean knives/cutting board, weighing scales, food-grade soaking containers, cooking vessel, stirring utensil, dehydrator trays, cabinet dehydrator, clean stand- up pouches and FORM-01. Do not start if an ingredient is missing, the scale is not working properly, or an ingredient identity is uncertain. Approved Formulation Percentage Quantity for 40 kg Batch Santol pulp 74.84% 29,936 g Sugar 25.00% 10,000 g C585 0.06% 24 g M245 0.04% 16 g TOTAL 100.00% 40,000 g Raw Material and Preparation • Use santol suitable for processing. Remove fruits with visible mold, serious decay, insect infestation, objectionable odor or foreign material. • Wash whole santol thoroughly with potable water. Make sure the steamer and trays are clean before loading. • Steam the santol for 30 minutes according to BAM Food OPC current process instruction. After steaming, allow the fruit to cool only enough for safe handling while keeping it protected from contamination. • Peel using clean hands/utensils. Remove unacceptable portions found during peeling. Slice into reasonably uniform bite-sized pieces so soaking and drying are more even. Processing Steps 1. Weigh 29,936 g santol pulp for the standard batch. If a different amount of santol is used, the other ingredients must be recalculated from the approved percentages; do not estimate. 2. Weigh sugar 10,000 g, C585 24 g and M245 16 g separately. Check the scale is zeroed before weighing. STOP if an ingredient or quantity is uncertain.
Page | 11 3. Prepare the osmotic mixture by thoroughly mixing the sugar, citric acid and metabisulfite so the minor ingredients are distributed as evenly as practical. 4. Combine the sliced santol and osmotic mixture by layers in a clean food- grade container. Cover the container. 5. Allow the santol to soak overnight or for at least 8 hours. Keep it covered and protected from insects, dust, chemicals and dirty water. 6. After the first soak, drain the osmotic solution into a clean cooking vessel. Keep the santol protected while the solution is heated. 7. Bring the drained osmotic solution to a boil. Once boiling, carefully add the sliced santol and continue heating for at least 5 minutes according to the current BAM process instruction. 8. After heating, soak the santol again in the solution for another 8 hours or overnight. Keep the container covered. 9. Drain the santol thoroughly before dehydration. Allow excess syrup to drain so the product does not enter the dehydrator heavily dripping. 10. Arrange pieces evenly on clean dehydrator trays. Avoid large piles and excessive overlapping so hot air can circulate. 11. Dehydrate at 60 degrees C for 4 hours according to the current BAM process instruction. Record the actual drying temperature and duration on FORM-01. 12. At the end of drying, inspect representative pieces from different trays. HOLD the batch if pieces are unusually wet, the dehydrator malfunctioned, drying was significantly interrupted, or the product has abnormal odor, appearance, mold or suspected contamination. 13. Condition the dried santol for at least 3 days according to the current BAM process. Keep it in a clean, dry, protected food-grade container. HOLD if condensation, mold or abnormal odor develops. 14. Pack 80 g per clean, dry stand-up pouch. Seal properly, check the seal, apply the correct label and batch/lot code, and submit FORM-01 for Manager/Owner release. Dried Santol - Key Control Points What to Control Staff Guidance / Acceptable Condition Action if Not Acceptable Raw santol Suitable fruit; no visible mold, serious decay or objectionable odor Remove/reject unacceptable fruit. Steaming 30 minutes - current BAM instruction If significantly interrupted/incorrect, STOP and inform Manager. Ingredient identity & weight Exact approved ingredients and amounts STOP. Do not guess or substitute.
Page | 12 M245 Correct identity; 16 g per standard 40 kg formulation STOP if identity or amount is uncertain. First soaking Covered; at least 8 hours/overnight Inform Manager if significantly shortened/interrupted. Heating Solution boiling before santol addition; santol heated at least 5 minutes HOLD if substantially underprocessed. Second soaking Covered; another at least 8 hours/overnight Inform Manager if significantly shortened/interrupted. Dehydration 60 degrees C for 4 hours - current BAM instruction; reasonably even tray loading HOLD/evaluate if interrupted, temperature incorrect or pieces remain unusually wet. Conditioning At least 3 days; no condensation, mold or abnormal odor HOLD affected batch. Packaging Clean/dry pouch; 80 g; good seal; correct label and batch code Repack/reseal acceptable product; HOLD questionable product. What staff record on FORM-01: batch/lot code, production date, formulation/ingredient quantities verified, first soaking period, heating treatment, second soaking period, dehydration temperature and duration, conditioning period, approximate finished yield/quantity, packaging/seal check, any deviation/HOLD decision and release decision. 4.4 Dried Strawberry Before starting: Read the full Dried Strawberry guide. Confirm that strawberries, sugar, C585 and M245 are available and correctly identified. Do not start if an ingredient is missing, its identity is uncertain, the scale is not working properly, or food-contact equipment is not clean. Approved Formulation Quantity Strawberries 30 kg Sugar 15 kg C585 30 g M245 18 g
Page | 13 Raw Material and Preparation • Use strawberries suitable for processing. Remove fruit with visible mold, serious decay, objectionable odor, pest damage or foreign material. • Using a sharp, clean stainless-steel knife, remove the calyx carefully. Avoid unnecessarily cutting away good strawberry flesh. • Wash the prepared strawberries with potable water and allow excess water to drain. Keep washed strawberries protected from dirty surfaces, dust, insects and unnecessary handling. • Use clean food-contact containers, cooking utensils and dehydrator trays. Make sure the weighing scales are clean, functioning and zeroed before weighing. Processing Steps 1. Measure the ingredients according to the approved formulation: 30 kg strawberries, 15 kg sugar, 30 g C585 and 18 g M245. Weigh C58 and M245 carefully; do not estimate these small quantities by eye. 2. Prepare the dry osmotic mixture by thoroughly mixing the sugar, citric acid and metabisulfite so the minor ingredients are distributed as evenly as practical through the sugar. 3. In a clean food-grade container, alternately layer the washed strawberries and the prepared sugar mixture. Example: strawberries - sugar mixture - strawberries - sugar mixture. Continue until all strawberries and mixture are used. Cover the container. 4. Soak overnight according to the current BAM process instruction. Keep the covered container protected from insects, dust, chemicals, dirty water and unnecessary handling. 5. After soaking, carefully remove the strawberries from the container and place them in a clean protected container. Transfer the resulting syrup to a clean cooking vessel. 6. Heat the syrup. When the syrup is boiling, carefully add the strawberries. 7. Continue simmering the strawberries in the syrup for 10 minutes according to the current BAM process instruction. Handle/stir carefully as needed to avoid unnecessary crushing of the fruit. 8. After simmering, drain the strawberries sufficiently before dehydration so excessive free syrup does not enter the dehydrator. 9. Arrange the strawberries on clean dehydrator trays with enough space for air circulation. Avoid large piles and excessive overlapping. 10. Dehydrate at 65 degrees C for 6.5 hours according to the current BAM process instruction. Record the actual drying temperature and duration on FORM-01.
Page | 14 11. After drying, inspect representative strawberries from different trays. The pieces should have a reasonably consistent dried condition and should have no visible mold, foreign material, objectionable odor or obvious contamination. HOLD the batch if the dehydrator malfunctioned, drying was significantly interrupted, or the product has unusually wet pieces or another abnormal condition. 12. For conditioning, place the dried strawberries in large clean food-grade plastic bags at at least 5 kg per bag. Close/protect the bags and condition for at least 3 days in a clean, dry area. 13. During conditioning, check for unusual moisture accumulation, condensation, mold, fermentation-like odor or other deterioration. If any of these appear, HOLD the affected product and inform the Manager or Owner. 14. After acceptable conditioning, prepare clean and dry stand-up pouches. Weigh 50 g of dried strawberries per pouch. 15. Add one approved moisture absorbent per pouch. Make sure the sachet is intact and is not opened, torn or mixed into the food. 16. Seal each pouch properly. Check that the seal is complete and that no strawberry piece or moisture-absorbent sachet is trapped in the sealing area. 17. Install the correct Dried Strawberry label and readable batch/lot code. Store the sealed product in a cool, dry place protected from moisture, direct sunlight, pests, chemicals and physical damage. 18. Complete FORM-01 and submit the batch for Manager/Owner review and release. Dried Strawberry - Key Control Points What to Control Staff Guidance / Acceptable Condition Action if Not Acceptable Raw strawberries Suitable fruit; no visible mold, serious decay, objectionable odor or foreign material Remove/reject unacceptable fruit. Calyx removal & washing Calyx removed with clean stainless-steel knife; strawberries washed with potable water Re-clean/re-sort before processing. Ingredient identity & weight 30 kg strawberries; 15 kg sugar; 30 g C585; 18 g M245 STOP. Do not guess or substitute. Correct before combining. Dry osmotic mixture Sugar, C585 and M245 thoroughly mixed before layering Remix before combining with strawberries. Layering & overnight soak Washed strawberries and mixture alternated in clean Inform Manager if process was
Page | 15 covered container; soaked overnight significantly interrupted or shortened. Syrup heating Syrup brought to boiling before strawberries are added Continue heating syrup before adding strawberries. Simmering Strawberries simmered in boiling syrup for 10 minutes HOLD if significantly underprocessed or process was interrupted. Tray loading Strawberries reasonably distributed for air circulation; no large piles Rearrange before drying. Dehydration 65 degrees C for 6.5 hours; actual temperature/duration recorded HOLD/evaluate if temperature/time was incorrect or drying was interrupted. Dried-product condition Reasonably consistent; no mold, objectionable odor, contamination or unusually wet pieces HOLD affected batch. Conditioning At least 5 kg per large food- grade plastic bag; at least 3 days; no condensation/mold/abnormal odor HOLD if deterioration or moisture accumulation is observed. Retail packing 50 g per stand-up pouch plus 1 intact approved moisture absorbent Correct weight/add sachet before sealing; replace damaged sachet. Seal, label & storage Complete seal; correct label/batch code; stored cool and dry Reseal/repack acceptable product; correct label before release. What staff record on FORM-01: batch/lot code, production date, formulation and ingredient quantities verified, overnight soaking completed, syrup boiling/simmering treatment (10 minutes), dehydration temperature and duration (65 degrees C / 6.5 hours), conditioning period (at least 3 days), approximate finished yield/quantity, 50 g pack weight and moisture-absorbent check, packaging/seal/label check, any deviation/HOLD decision and release decision. Important process note: The overnight soak, 10-minute simmer, 65 degrees C for 6.5 hours dehydration, at least 3-day conditioning, 50 g retail pack and one moisture absorbent per pouch are BAM Food OPC's current operating instructions
Page | 16 supplied for this revision. This SOP does not independently establish the drying time/temperature as a scientifically validated shelf-stability critical limit. Any change to formulation, process, conditioning, packaging or moisture-control system requires Owner authorization and appropriate technical review. 4.5 Dehydrated Vegetable Pear / Chayote Before starting: Confirm that chayote, sugar, C585, M245, salt and turmeric powder are available and correctly identified. The formulation below comes from the current Dehydrated Chayote recipe supplied for this revision. Approved Formulation Percentage Quantity Chayote 74.63% 33,583.50 g Sugar 25.00% 11,250.00 g C585 0.09% 40.50 g M245 0.04% 18.00 g Salt 0.20% 90.00 g Turmeric powder 0.04% 18.00 g TOTAL 100.00% 45,000.00 g Raw Material and Preparation • Use chayote suitable for processing and free from visible mold, serious decay, pest damage, objectionable odor and foreign material. • Wash with potable water before cutting or slicing. Use clean knives/slicer, trays, containers and other food-contact equipment. • Prepare reasonably uniform pieces according to the current Owner-approved chayote process so treatment and drying can be as even as practical. • Weigh every ingredient carefully. C585, M245 and turmeric powder are present in small quantities and must not be estimated by eye. Processing Steps - Controlled Instruction Required The supplied Dehydrated Chayote sheet provides the approved formulation but does not provide the actual processing sequence, soaking method, heating/blanching treatment, dehydration temperature/time, conditioning period or package weight. For this reason, those values are NOT invented in this SOP. Processing staff shall use the latest Owner-approved Dehydrated Chayote process sheet until those instructions are formally incorporated into this manual. 1. Confirm and weigh the formulation exactly as shown above. STOP if any ingredient identity or quantity is uncertain. 2. Prepare and cut the chayote only according to the current approved product sheet. Keep prepared chayote protected from contamination.
Page | 17 3. Follow only the approved pretreatment/osmotic treatment sequence and approved holding times. Do not copy the Dried Santol soaking/heating steps unless the Owner has formally approved them for chayote. 4. Load clean dehydrator trays evenly and follow the approved chayote drying temperature, time and finished-product dryness specification. 5. After drying, protect the product from moisture. HOLD any batch with mold, abnormal odor, contamination, unusually wet pieces or a significant drying- process deviation. 6. Package only according to the approved chayote package type and net weight. Check seal, label and batch/lot code before release. Dehydrated Chayote - Key Control Points What to Control Staff Guidance / Acceptable Condition Action if Not Acceptable Raw chayote Suitable, clean raw material; no mold/serious decay Remove/reject unacceptable material. Ingredient identity & weight Exact approved formulation: chayote, sugar, citric acid, metabisulfite, salt and turmeric powder STOP. Do not guess or substitute. Minor ingredients C585 39.01 g; M245 65.01 g; turmeric powder 17.34 g per listed standard formulation STOP if identity or amount is uncertain. Piece preparation Reasonably uniform according to approved product sheet Correct before pretreatment/drying. Pretreatment/process Must match current Owner-approved chayote process sheet HOLD if required treatment was omitted, changed or substantially interrupted. Dehydration Approved temperature/time and final dryness specification must be followed and recorded HOLD if drying conditions are not met or product remains unusually wet. Finished product No mold, abnormal odor, contamination or foreign material HOLD affected batch. Packaging Approved package/net weight; clean, dry and properly sealed; correct batch code Correct before release.
Page | 18 What staff record on FORM-01: batch/lot code, production date, formulation/ingredient quantities verified, approved pretreatment/process used, dehydration temperature and duration, finished-product condition, approximate yield/quantity, packaging/seal check, any deviation/HOLD decision and release decision. Important: Before this Chayote section is treated as a complete stand-alone work instruction, BAM Food OPC should add the approved slicing specification, pretreatment/soaking or heating steps, dehydration temperature and time, finished-product dryness criterion, conditioning method if used, and package net weight from the controlled process sheet. 4.6 Other Products For products without a complete current formulation AND process instruction in this manual, processing staff shall use the latest Owner-approved product sheet. The product sheet must state the formulation, preparation, processing conditions, packaging and product-specific acceptance criteria. Do not copy processing conditions from another product unless specifically approved. Product Current Guidance Retained from Existing Manual Strawberry-Lemon Marmalade Use fully ripe strawberries and Meyer lemon; clean/de-seed lemon; slice; cook with continuous stirring to spreadable consistency; immediate filling. Existing sheet lists water-bath schedules by jar size. Use only the current approved product sheet. Passion Fruit Honey Tea Use suitable ripe passion fruit; wash and depulp without white pith; weigh ingredients; cook according to the current approved product sheet; fill with reasonably uniform pulp/syrup distribution; use only the approved jar- size process. Tomato Marmalade Use suitable ripe tomatoes and lemon; wash/de-seed; puree/slice as specified; cook with continuous stirring; use only the current approved jar-size process. Dehydrated Products Follow the current approved product sheet for preparation, pretreatment, loading, drying temperature/time and final dryness specification. Cool
Page | 19 protected from moisture and package promptly. Important process note: Water-bath times retained in BAM's existing product sheets are current operating instructions. This simplified manual does not independently establish them as validated scheduled processes or HACCP critical limits. Changes to formulation, acid/preservative system, jar size, fill weight, headspace or thermal schedule require technical review before commercial use. 5. Packaging, Product Release and Storage Packaging is the final protection of the food. A good product can still become unsafe or unacceptable if the jar, lid, seal, label or storage condition is poor. • Use only clean, intact and correct packaging and the current approved label. • Apply a batch/lot code that can be traced to FORM-01. • Check product name/variant, net content, label, jar/package condition and closure before release. • Segregate leaking, damaged, mislabeled, moldy, contaminated or otherwise questionable units as HOLD/REJECTED. • Store released products clean, dry, protected from sunlight, heat, moisture, pests and chemicals. Use FEFO. • Retain at least one representative sample per commercial batch through the tagged shelf-life/expiry period for complaint and shelf-life reference. 6. Problems, Returns, Complaints and Recall When something goes wrong, do not hide it and do not try to fix the records. Protect the product first, tell the Manager or Owner, and record the problem on FORM-02. Routine acceptable production does not need separate deviation, CAPA, complaint and recall forms. FORM-02 Incident / Hold / Complaint / Recall Record is completed only when something unusual occurs. • HOLD means: STOP using, selling, delivering or mixing the affected product with good stock. Put it in a separate area and mark it clearly as HOLD. Use HOLD for a wrong ingredient or quantity, suspected contamination, mold/spoilage, foreign material, serious packaging/seal failure, interrupted/incorrect process, or another important safety/quality concern. Tell the Manager or Owner immediately. • Returned/bad-order products are kept separate from saleable stock and are not reworked for human food.
Page | 20 • Record product, batch, quantity, problem, immediate action and final decision on FORM-02. • For a possible recall, the Owner decides the scope with the Manager; use batch and inventory/dispatch records to identify affected stock and destinations. • Do not erase or alter original records to hide a mistake. Correct paper records with a single line, corrected entry and initials/date. 7. Inventory and Traceability Traceability means being able to answer two simple questions: 'Where did the ingredients come from?' and 'Where did the finished product go?' For a micro-business, inventory records should also serve as distribution traceability. Avoid maintaining separate forms that repeat the same movement. • Use FORM-03 Stock Movement & Sales Record for finished-product IN/OUT movements, outlet/destination, quantity and batch/lot where practical. • Use FEFO. The Manager performs a physical inventory reconciliation at least monthly or at a practical regular interval based on operations. • Significant unexplained variances are recorded on FORM-02. • Keep supplier invoices/delivery documents together with production records so raw materials can be traced back when needed. 8. Confidentiality and Photography Control BAM's formulations and processing methods are company information. Workers and trainees may learn them only for their assigned work and must not share them without permission. All regular employees, part-time/casual workers, OJTs, interns and other persons given access to BAM Food OPC's non-public operations shall protect confidential information. • Confidential information includes formulations, ingredient percentages/codes, raw materials and suppliers, processing methods, trials/R&D, equipment settings, batch and business records, costing, product concepts and non- public packaging/label designs. • Photography, video, audio recording, screenshots or other recording of production areas, formulations, raw materials, documents or restricted information is prohibited unless authorized by the Owner or Manager.
Page | 21 • Confidential information shall not be copied, posted, uploaded, messaged, removed or discussed with unauthorized persons. • Confidentiality continues after employment, part-time work or OJT/internship ends. Simple End-of-Production Check 1. Product was made using the correct product guide. 2. Jars/packages are intact, properly closed and correctly labeled/coded. 3. Any questionable product is separated and marked HOLD. 4. One retention sample is kept when required. 5. FORM-01 is completed and submitted for Manager/Owner review. 6. Ingredients are closed and returned to proper storage. 7. Equipment, utensils and the work area are cleaned and left orderly. 8. Waste is removed and chemicals are returned to designated storage. 9. Minimum Records - Lean System Only the records below are routinely required. The purpose is not to create paperwork; it is to keep enough evidence to trace a batch, show that important process steps were followed, and respond properly if a problem occurs. Record When Used Why It Is Kept FORM-01 Batch Production & Release Record Every commercial batch Primary evidence of formula, key process controls, packaging, batch code, yield, deviations and release. FORM-02 Incident / Hold / Complaint / Recall Record Only when an abnormal event, complaint, return, hold, rejection, recall or significant deviation occurs Avoids separate forms for rare events while preserving corrective-action evidence. FORM-03 Stock Movement & Sales Record When finished stock moves or is sold/distributed Inventory control plus one- step-forward traceability.
Page | 22 FORM-04 Monthly GMP / Facility Check Once monthly and after a major problem/change Replaces multiple routine sanitation, pest, equipment and internal-audit logs. FORM-05 Confidentiality & Non- Photography Undertaking Once on engagement, and renewed if policy materially changes Protects trade secrets and restricted photography. Supplier invoices/delivery receipts and relevant certificates As received Provides receiving and one- step-back traceability without duplicate receiving transcription. Water test/potability evidence, maintenance/calibratio n/service records When performed/received Evidence for infrequent but important controls. Records intentionally removed as separate routine forms: daily hygiene log, separate produce-preparation log, separate cooking/water-bath log, separate packaging log, separate finished-product release log, separate equipment cleaning log, separate calibration log, separate retention-sample log, separate pest log, separate deviation/CAPA form, and separate recall form. Their essential information is either checked on FORM-01/FORM-04, retained as source documents, or recorded on FORM-02 only when an event occurs. QUICK MEANINGS FOR STAFF STOP = do not continue the questionable step. HOLD = keep affected product separate and do not sell or release it. RELEASED = the Manager or Owner has reviewed the batch and allows it into saleable inventory. N/A = not applicable. F
Page | 23 FORM-01 Batch Production & Release Record Field Entry Product / Variant Batch/Lot Code Production Date Approved Formula/Guide Version Raw material / ingredient lots (where available) Key ingredient quantities verified [ ] Yes [ ] No Coded ingredients re-checked [ ] C585 [ ] G230 [ ] S370 [ ] A240 [ ] N/A Pre-op: personnel fit/hygienic, area/equipment clean, correct labels/packaging [ ] Acceptable Process start / end Key product-specific process observations / times Water-bath or dehydration setting/duration, if applicable Packaging/seal/label/batch code check [ ] Acceptable Approx. finished yield / quantity Retention sample kept [ ] Yes [ ] N/A Deviation/problem? [ ] No [ ] Yes - complete FORM-02 Processed by Reviewed / Released by Manager or Owner Release decision [ ] RELEASED [ ] HOLD
Page | 24 FORM-02 Incident / Hold / Complaint / Recall Record Field Entry Date / Time Product / Batch / Quantity Type [ ] Process deviation [ ] Hold/Rejection [ ] Return/BO [ ] Complaint [ ] Recall/Withdrawal [ ] Pest/Glass/Equipment/Chemical [ ] Other What happened / complaint Immediate action / product segregation Likely cause, if known Correction / corrective action Disposition [ ] Release [ ] Rework if specifically permitted [ ] Dispose [ ] Return [ ] Recall/Withdraw [ ] Other Destinations / quantities affected or recovered, if recall Manager review Owner approval for serious/recall cases
Page | 25 FORM-03 Stock Movement & Sales Record Date Product / Variant Batch/Lot Qty IN Qty OUT / Sold Destination / Outlet Balance / Remarks Initials Monthly physical count / reconciliation: Date __________ Expected __________ Actual __________ Variance __________ Manager __________ FORM-04 Monthly GMP / Facility Check Check OK / Action Needed Personnel hygiene practices and handwashing followed Processing/storage areas clean and orderly; wet/dry separation maintained Food-contact equipment clean and in good condition Scales/thermometers functioning; calibration/verification status acceptable where applicable No pest evidence; doors/screens/storage practices acceptable Chemicals separated and labeled Ingredients/packaging identified, protected and within acceptable shelf life Finished products protected; FEFO and HOLD segregation followed Water potability evidence current/acceptable Labels, batch coding and confidentiality controls followed Corrective actions required / due date Checked by Manager Owner review (if significant issue)
Page | 26 FORM-05 Confidentiality and Non-Photography Undertaking I acknowledge that through my employment, part-time/casual work, OJT, internship or other assignment with BAM Food OPC, I may access confidential and proprietary information. I agree to keep confidential all non-public formulations, ingredient percentages/codes, raw materials and suppliers, production processes, trials, records, costing, product concepts and other non- public business information. I shall not disclose, copy, photograph, record, upload, post, transmit, remove or use confidential information for an unauthorized purpose. I understand that photographs, videos, audio recordings and screenshots inside production or restricted areas are prohibited unless specifically authorized by the Owner or Manager. This obligation continues after my work or training ends. Name: __________________________________________ Status: [ ] Regular [ ] Part-Time/Casual [ ] OJT/Intern [ ] Other: _____________ School/Institution (if applicable): ______________________________________ Signature: __________________________________ Date: ________________ Accepted by Owner/Manager: ___________________ Date: _______________ Record Retention and Corrections • Complete records when the activity occurs. Do not backdate. • Use permanent ink for paper records. Mark unused required fields N/A where appropriate. • Correct errors with one line through the original entry, write the correction, then initial/date. Do not erase or obscure the original entry. • Keep batch, traceability, complaint/recall and relevant supporting records for at least the product shelf-life plus an appropriate investigation period and any longer applicable regulatory requirement.
