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▾ Factory SOPs

Recipe	SOP Code	Brand	Version	Steps	Legacy SOP	Recipe stage	Owner	SOP status

Factory Standard Operating Procedure

Hasawi Marinade

SOP-2025-009 · Based on Recipe v2.1 · Issued 15 Mar 2025

Approved for Production

Brand

Maestro

Batch Size

Per run

Scale Factor

×N

Storage

Frozen −18°C

Shelf Life

12 Months

Production Steps8 Steps

1

🧼 Hygiene🌡️ Temperature

Equipment Preparation & Sanitation

Ensure all mixing vessels, pipelines and filling equipment are CIP-cleaned and sanitised per SAN-001 protocol before commencing production. Verify equipment calibration logs are up to date.

CIP Temperature

85°C minimum

Hold Time

20 minutes

Responsible

Sanitation Lead

2

⚖️ Weigh✅ QC Check

Raw Material Weighing & Verification

Weigh all dry ingredients on calibrated floor scales. Each ingredient must be verified against the batch ticket by two operators (4-eyes check). Record actual weights in production log.

Total Batch

400.000 kg

Scale Tolerance

±0.050 kg

Verification

4-eyes check

🛑 CCP 1 — Correct ingredient weights are a Critical Control Point. Any deviation >0.5% requires supervisor sign-off before proceeding.

3

⏱️ Time

Dry Blend — Spice & Seasoning Mix

Add all dry spices and seasoning ingredients to the ribbon blender in the order specified on the batch ticket. Blend until homogeneous. Sieve through 2mm mesh before transfer.

Blender Speed

Medium — 45 RPM

Blend Time

8 minutes

Mesh Size

2 mm

4

🌡️ Temperature⚠️ Danger

Base Liquid Preparation

Combine water and vinegar in the jacketed mixing vessel. Heat to 60°C while stirring at low speed. Add salt and dissolve completely. Verify pH before proceeding.

Target Temp

60°C

Stirrer Speed

Low — 20 RPM

Target pH

3.8 – 4.4

🛑 CCP 2 — pH must be verified in-line before adding dry blend. Log result on QA checkpoint sheet QA-F-002.

5

💡 Tip⏱️ Time

Incorporation of Dry Blend into Base

Slowly add the dry blend to the liquid base while mixing at medium speed. Ensure no clumping — if lumps observed, increase speed briefly then return to medium. Add oil phase last.

Addition Rate

Slow — over 5 min

Mixer Speed

Medium — 35 RPM

Mix Time

15 minutes total

6

✅ QC Check⚠️ Danger

In-Process QC Check

QA technician takes sample for pH, Brix and viscosity checks. Product must be within spec before proceeding to filling. Organoleptic check by QA and NPD sign-off required.

pH Target

3.8 – 4.4

Brix Target

18 – 22 °Bx

Viscosity

800–1200 cP

⚠️ If any parameter is out of spec, HOLD product and notify QA Manager and NPD immediately. Do not proceed to filling.

7

⚖️ Weigh📸 Photo Check

Filling & Packaging

Fill into designated packaging format per pack spec. Check fill weights every 15 minutes. Apply batch code and best-before date label. Confirm label compliance before pallet build.

Fill Weight

Per pack spec

Weight Check

Every 15 min

Label Check

Every pallet

8

🌡️ Temperature⚠️ Danger

Blast Freezing & Storage

Transfer filled and sealed product to blast freezer immediately after packing. Freeze to core temperature of −18°C before palletising. Store in frozen warehouse at −18°C ±2°C.

Blast Freeze

−35°C / 90 min

Core Temp Target

−18°C

Storage

−18°C ±2°C

🛑 CCP 3 — Core temperature must reach −18°C before product leaves blast freezer. Record on HACCP log HA-F-008.

Sign-off

Production Supervisor

QA Technician

Date & Batch No.

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Branch SOPs

	Product Name	SOP Code	Brand	Category	Version	Steps	Status

Cost per kg by BrandWhere margin is won or lost

Waste by RecipeTarget these for reformulation

Most Expensive RecipesCost optimization targets

QA Fail RateFormula or process issues

Ingredient CommonalityBulk purchasing leverage

Development PipelineDays from draft to approved

Cost Trend by BrandVersion-over-version cost change

Substitution OpportunitiesExpensive ingredients in few recipes

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ACTIVE

Approved and launched. This is what the branches are making and selling right now, so treat changes to it as changes to a live product.

IN PROGRESS

You have pressed Submit for Review. Do that when you are sure the build is finished and correct, not to park it. It starts two things at once: Admin reviews it for approval, and Finance checks the costing. Both are emailed automatically. Nothing is in the branches yet.

DRAFT

Still being built. Add the components, weights, Oracle codes and the photo. Nobody outside R&D needs to look at it yet.

INACTIVE

Was live, now withdrawn. Kept so the history and the costing stay on record. It can be reactivated.

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