HACCP Plan Grower Farm
HACCP Plan Grower Farm
HACCP Plan Grower Farm
com
1. Introduction to HACCP 2. HACCP Scope 3. HACCP Team 4. Definitions 5. Methodology 6. Product Identification and Intended Use and Process 7. Product Descriptions 8. Flow Diagram for Farm 9. Risk Analysis Table 10. CCP Decision Tree 11. Verification Table 12. Validation Table
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Hazard Analysis Critical Control Point, or HACCP, is a system, which gives us a pro-active common sense approach to the safety management of our food products. HACCP was originally designed in the early days of the American manned space programme, and was developed by the Pillsbury Company, NASA and the United States Army laboratories, to ensure the Microbiological safety of the astronauts food. The HACCP system was launched publicly in 1971, and is designed to identify and control hazards that may occur anywhere in a food processing operation. The benefits of the HACCP system are as follows: A Preventative System A Systematic Approach Helps demonstrate Due Diligence Internationally accepted Strengthens Quality Management Systems Facilitates regulatory inspection/external audits Demonstrates Management commitment
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The purpose of this Farms food safety program is to identify and control, prevent and eliminate food safety hazards. The HACCP Team have identified the Scope of this study as being: From the purchase of the seed or propagation materials through to the final harvesting and collection of produce by packing facilities. The HACCP plan provides an overview of the process involved in: For: Intake of stock Growing Harvesting Storage Packing of stock Dispatch of product Strawberries Raspberries Blueberries Blackberries
This HACCP plan has been prepared in accordance with: CODEX Alimentarius Guidelines 97/13A for HACCP European Communities (Hygiene of Foodstuffs) Regulations 2006
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Name
Position
Team Leader Grower General Manager
Qualifications
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Definition A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Practices and procedures forming the basis of preventable actions: Receiving, Storage & Transport (e.g. procedure for receipt, approved supplier programme etc.) Calibration & Maintenance Cleaning Pest control Staff training & Personnel Product Identification, Traceability & Recall Premises (buildings & site) A tabulated record of all Hazards that affect or have the potential to affect the safety of the products under analysis. The significance of a hazard is rated as low, medium or high and control measures for each hazard are stated. Hazards identified in the risk analysis table as being of medium or high significance and their respective control measures are transferred to the HACCP table. The critical limit of these hazards is specified. Details of who will monitor the critical limit to make sure it is not broken are given. Actions to be taken when critical limits are broken are also given. Records of monitoring activities are listed. Severity: the consequences of the Hazard occurring H High Life Threatening or causing severe illness / injury M- Medium Moderate illness/injury not life threatening L- Low- Mild illness/injury, not life threatening Likelihood: the likelihood of the hazard occurring H- High Likely to occur often M- Medium May occur sometimes L Low Unlikely to occur Significance. The consequences of the hazard occurring when both the severity and likelihood are high, the significance is high.
HACCP Table
Sev
Lik
Sig
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The flow chart has been designed so that each step has been allocated a number. All steps that are repeated throughout the process have been allocated the same number to save repetition in the risk analysis table. The method used to establish CCPs within this HACCP plan has been based on the significance of each hazard as determined by the risk analysis table. Hazards which can be controlled, Prevented or eliminated by the application of Per-Requisite Programme are not included in the HACCP table. Therefore these hazards have been identified in the risk analysis and have not been carried forward to the HACCP table as CCPs. All other hazards not controlled by PRP and defined as highly significant within the Risk Analysis Table have been carried over to the HACCP table as a CCP. These hazards are all monitored and a record of that activity maintained. Hazards defined as less than significant within the Risk Analysis Table are not carried over to the HACCP Table and may not be monitored or a record maintained. TOTAL RISK = LIKELIHOOD x SEVERITY Likelihood 1 = Improbable event once every five years 2 = Remote possibility once every year 3 = Occasional event once per month 4 = Probable event once per week 5 = Frequent event once per day Severity 1 = Negligible no impact or not detectable 2 = Marginal only internal company target levels affected 3 = Significant Impact on critical limits 4 = Major Impact on customers (may not be the public) 5 = Critical public health risk / public product recall
Likelihood 1 2 3 4 5
Severity 1 1 2 3 4 5
2 2 4 6 8 10
3 3 6 9 12 15
4 4 8 12 16 20
5 5 10 15 20 25
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Strawberries - fruit
See individual fruit specification for strawberries Predominantly eaten raw. Can be eaten intact or peeled and/or cut. Grown above ground, Inside. Grown above ground, outside. Planting, Picking, Packing None None None Various forms including Loose in punnets, sizes vary depending on customer requirements 227g, 300g, 400g 454g, 500g Product Name, Display Until, Origin, Variety, Barcode, Address all as per specification Storage conditions - chill storage 3oC 8oC 3oC 8oC Chill storage 3 days from manufacture Within country product is transported in refrigerated enclosed trucks. Generally fruit crops are transported in refrigerated sea containers or palletised in the bulk holds of ships. They can also be transported by air freight (e.g. berries). Generally consignments do not consist of more than one product. Predominantly eaten raw. May be cooked. All groups may consume these raw and/or cooked. Not washed or refrigerated in the home and/or at the distribution centre/retailer.
Processing Procedure Food Additives Processing Aids Preservatives (Minimum concentration) Packaging:
Labelling requirements relating to Food Safety Durability & storage conditions: Method of Preservation (pH, aw , time temp etc) Product Shelf Life Method of distribution:
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Raspberries - fruit
See individual fruit specification for Raspberries Predominantly eaten raw. Can be eaten intact or peeled and/or cut. Grown above ground, Inside. Grown above ground, outside. Planting, Picking, Packing None None None Various forms including Loose in punnets, sizes vary depending on customer requirements 125g, 170g, 250g, Product Name, Display Until, Origin, Variety, Barcode, Address all as per specification Storage conditions - chill storage 3oC 8oC 3oC 8oC Chill storage 3 days from manufacture Within country product is transported in refrigerated enclosed trucks. Generally fruit crops are transported in refrigerated sea containers or palletised in the bulk holds of ships. They can also be transported by air freight (e.g. berries). Generally consignments do not consist of more than one product. Predominantly eaten raw. May be cooked. All groups may consume these raw and/or cooked. Not washed or refrigerated in the home and/or at the distribution centre/retailer.
Processing Procedure Food Additives Processing Aids Preservatives (Minimum concentration) Packaging:
Labelling requirements relating to Food Safety Durability & storage conditions: Method of Preservation (pH, aw , time temp etc) Product Shelf Life Method of distribution:
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Blackberries - fruit
See individual fruit specification for Blackberries Predominantly eaten raw. Can be eaten intact or peeled and/or cut. Grown above ground, Inside. Grown above ground, outside. Planting, Picking, Packing None None None Various forms including Loose in punnets, sizes vary depending on customer requirements 125g, 150g Product Name, Display Until, Origin, Variety, Barcode, Address all as per specification Storage conditions - chill storage 3oC 8oC 3oC 8oC Chill storage 3 days from manufacture Within country product is transported in refrigerated enclosed trucks. Generally fruit crops are transported in refrigerated sea containers or palletised in the bulk holds of ships. They can also be transported by air freight (e.g. berries). Generally consignments do not consist of more than one product. Predominantly eaten raw. May be cooked. All groups may consume these raw and/or cooked. Not washed or refrigerated in the home and/or at the distribution centre/retailer.
Processing Procedure Food Additives Processing Aids Preservatives (Minimum concentration) Packaging:
Labelling requirements relating to Food Safety Durability & storage conditions: Method of Preservation (pH, aw , time temp etc) Product Shelf Life Method of distribution:
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Blueberries - fruit
See individual fruit specification for Blueberries Predominantly eaten raw. Can be eaten intact or peeled and/or cut. Grown above ground, Inside. Grown above ground, outside. Planting, Picking, Packing None None None Various forms including Loose in punnets, sizes vary depending on customer requirements 125g, 150g, 170g Product Name, Display Until, Origin, Variety, Barcode, Address all as per specification Storage conditions - chill storage 3oC 8oC 3oC 8oC Chill storage 3 days from manufacture Within country product is transported in refrigerated enclosed trucks. Generally fruit crops are transported in refrigerated sea containers or palletised in the bulk holds of ships. They can also be transported by air freight (e.g. berries). Generally consignments do not consist of more than one product.
Processing Procedure Food Additives Processing Aids Preservatives (Minimum concentration) Packaging:
Labelling requirements relating to Food Safety Durability & storage conditions: Method of Preservation (pH, aw , time temp etc) Product Shelf Life Method of distribution:
Predominantly eaten raw. May be cooked. All groups may consume these raw and/or cooked. Not washed or refrigerated in the home and/or at the distribution centre/retailer.
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6 a. Waste
7. Harvesting
8 a. Packaging Input
6 b. Recycled waste
9. Dispatch
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Process Step
1. Plant Intake 1. Plant Intake 1. Plant Intake
Potential Hazard
Microbiological contamination of plants Chemical Contamination by pesticides Physical Contamination from pests Foreign body/Dust contamination from production environment Microbiological Contamination from personnel
Sev
4 5 5
Lik
1 1 1
Sig*
4 5 5
CCP
NO NO NO
Control Measures
Plants sourced from accredited suppliers. Plant passports accompany all material accepted on site. Plants sourced from accredited suppliers. Plant passports provide the history / traceability of used chemicals. Plants sourced from accredited growers. Plant passports accompany plants to detail they are pest free. Hygiene procedures in place. Glass procedures in place Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place All water used in the growing area passes through a UV filter. Water samples are taken before and after the UV filter to verify that the system is working. Samples are taken every 2 weeks for verification. This is monitored externally and advice and recommendations are DATE: DATE:
NO
Physical Contamination from personnel Foreign body/Dust contamination from production environment Microbiological Contamination from water contaminated
NO
NO
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Issued: Reviewed: Next Review: Page 14 of 24 given from the service provider where results are unsatisfactory. A service contract is in place to ensure that the filters are maintained and changed when necessary. All biological controls are purchased from approved suppliers with certificates of conformance Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place Cleaning schedules are in place to ensure that all spray equipment is cleaned sufficiently preventing micro spread. Trained personnel only permitted to use chemicals. Chemicals records are kept on file. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place Personnel entering the facilities are trained to DATE: DATE:
Contaminated product entering production could affect product Contaminated product entering production could affect product Contaminated product entering production could affect product Contaminated product entering production could affect product Contaminated product entering production could affect product Contaminated product entering production could affect product Contaminated
NO
NO
4. Crop Walking
Physical Contamination from personnel Foreign body/Dust contamination from production environment Microbiological Contamination from unclean spraying devices Chemical Contamination from overuse of plant protection products Physical Contamination from personnel Foreign body/Dust contamination from production environment Microbiological Contamination from VALIDATED BY: VALIDATED BY:
NO
5. Intermittent Spraying if infestation noticed 5. Intermittent Spraying if infestation noticed 5. Intermittent Spraying if infestation noticed
NO
NO
NO
3 POSITION: POSITION:
NO
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Issued: Reviewed: Next Review: Page 15 of 24 wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. All staff are trained on hand-washing procedures through basic food safety training during the induction. Personal Hygiene procedures in place Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Glass procedures in place DATE: DATE:
plants
personnel
Physical Contamination from personnel Foreign body/Dust contamination from production environment Microbiological Contamination from personnel
NO
6 a. Waste
NO
6 a. Waste
Physical Contamination from personnel Foreign body/Dust contamination from production environment Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from personnel handling fruit Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment VALIDATED BY: VALIDATED BY:
NO
6 b. Recycled waste
NO
7. Harvesting
NO
7. Harvesting
NO
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Issued: Reviewed: Next Review: Page 16 of 24 NO Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors All crates and liners are constructed of food grade plastic. Packing procedures in place. Packaging is sourced from approved suppliers Supplier approval procedures in place. Certificates confirming food grade packaging in place. Primary packaging is made from food grade material. Packaging is sourced from approved suppliers. Supplier approval procedures in place. Certificates confirming food grade packaging in place. Packaging is sourced from approved suppliers. Packaging is only taken into the harvesting areas when needed. It is not left in the area when not in use. All opened packaging, which hasnt been fully used, is recovered and stored sufficiently to prevent the risk of pest infestation. Packaging is sourced from approved suppliers. Supplier approval procedures in place. Certificates confirming food grade packaging in place. Wood policy is in place to ensure that only good quality, fully intact pallets are used for stacking fruit. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. DATE: DATE:
Microbiological Contamination from personnel handling the fruit Chemical Contamination from non food grade crates / liners Microbiological Contamination from packaging used to pack and label products Chemical Contamination from non food grade material
5 5
1 1
5 5
NO NO
8 a. Packaging input
NO
8 a. Packaging input
NO
9. Dispatch
Physical Contamination from personnel Foreign body/Dust contamination from production environment
NO
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The CCP decision tree is as follows: Q1 - Do control measure(s) exist for the identified hazard? YES Q2 - Is the step specifically designed to eliminate or reduce a hazard to an acceptable level? YES NO
YES
Q4 - Will a subsequent step eliminate or reduce the likely occurrence of the hazard to an acceptable level? YES NO
NOT A CCP CCP CCP Determination: A CCP is a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. The information collated during the hazard analysis allows for the identification of CCPs. To assist in the decision making process of determining CCPs a CCP decision tree was used.
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Process Step
1. Plant Intake 1. Plant Intake 1. Plant Intake 2. Plant into Pots / Bags
Potential Hazard
Microbiological contamination of plants from the plant suppliers Chemical Contamination by pesticides above the MRL levels specified for each chemical Physical Contamination from pests Microbiological Contamination from personnel handling the plants.
Q2
NO NO NO NO
Q3
NO NO NO NO
Q4
N/A N/A N/A N/A
CCP (Y/N)
NO NO NO NO
Control Measures
Plants sourced from accredited suppliers. Plant passports accompany all material accepted on site. Plants sourced from accredited suppliers. Plant passports provide the history / traceability of used chemicals. Plants sourced from accredited growers. Plant passports accompany plants to detail they are pest free Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. All water used in the growing area passes through a UV filter. Water samples are taken before and after the UV filter to verify that the system is working. Samples are taken every 2 weeks for verification. This is monitored externally and advice and recommendations are given from the service provider where results are unsatisfactory. A service contract is in place to ensure that the filters are maintained and changed when necessary. All biological controls are purchased from approved suppliers with certificates of conformance DATE: DATE:
Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from water contaminated with Fusarium, coliforms, Ecoli or Salmonella
YES
NO
NO
N/A
NO
YES
NO
NO
N/A
NO
Microbiological Contamination from insects carrying disease VALIDATED BY: VALIDATED BY:
YES
NO
NO
YES
NO
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4. Crop Walking
4. Crop Walking
5. Intermittent Spraying if infestation noticed 5. Intermittent Spraying if infestation noticed 5. Intermittent Spraying if infestation noticed 6. Pruning & turning of plants
Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from unclean spraying devices Chemical Contamination from overuse of plant protection products Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from personnel handling, pruning or training plants Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from personnel handling, pruning or training plants VALIDATED BY: VALIDATED BY:
YES
NO
NO
N/A
NO
NO NO NO
NO NO NO
NO NO NO
YES
NO
NO
N/A
NO
YES
NO
NO
N/A
NO
YES
NO
NO
N/A
NO
Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Cleaning schedules are in place to ensure that all spray equipment is cleaned sufficiently preventing micro spread. Trained personnel only permitted to use chemicals. Chemicals records are kept on file. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors. All staff trained and records retained on DATE: DATE:
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Issued: Reviewed: Next Review: Page 21 of 24 personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. All staff are trained on hand-washing procedures through basic food safety training during the induction. Personal Hygiene procedures in place Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files. Personnel entering the facilities are trained to wash hands. Personal Hygiene procedure in place. Hand washing signs are visible to all staff and visitors All crates and liners are constructed of food grade plastic. Packing procedures in place. Packaging is sourced from approved suppliers Supplier approval procedures in place. Certificates confirming food grade packaging in place. Primary packaging is made from food grade material. Packaging is sourced from approved suppliers Supplier approval procedures in place. Certificates confirming food grade packaging in place. Packaging is sourced from approved suppliers. Packaging is only taken into the harvesting areas DATE: DATE:
6 a. Waste
6 b. Recycled waste
7. Harvesting 7. Harvesting
Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from personnel handling fruit Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment Microbiological Contamination from personnel handling the fruit Chemical Contamination from non food grade crates / liners Microbiological Contamination from packaging used to pack and label products Chemical Contamination from non food grade material
YES
NO
NO
N/A
NO
YES YES
NO NO
NO NO
N/A N/A
NO NO
YES
NO
NO
N/A
NO
NO NO NO
NO NO NO
NO NO NO
8 a. Packaging input
Physical contamination from foreign bodies within packaging or from the surrounding VALIDATED BY: VALIDATED BY:
YES
NO
NO
N/A
NO
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Issued: Reviewed: Next Review: Page 22 of 24 when needed. It is not left in the area when not in use. All opened packaging, which hasnt been fully used, is recovered and stored sufficiently to prevent the risk of pest infestation Packaging is sourced from approved suppliers Supplier approval procedures in place. Certificates confirming food grade packaging in place. Wood policy in place to ensure that only good quality, fully intact pallets are used for stacking fruit Hygiene and Personal Hygiene procedures are in place to ensure that no foreign bodies are introduced into the growing area. All staff trained and records retained on personnel files.
area
9. Dispatch
Physical Contamination from damaged wooden pallets Physical Contamination from personnel handling the crop. Foreign body/Dust contamination from production environment
YES
NO
NO
N/A
NO
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Verify flow chart Review Hazards Review trade requirements through EU portal / FSAI Review customer complaints & rejections Validate critical limits Review staff training
Description All annual Global Gap (or similar) must be up to date to ensure that system is followed & limits are adhered too Follow flow chart through the production run HACCP team reviews hazards HACCP team reviews requirements Assess any customer complaint records to highlight any deficiencies of the system Check that critical limits are still appropriate carry out literature search Review staff training needs in HACCP / Food Safety awareness to ensure training records up to date
Records Annual Certificates on supplier file Update flow chart HACCP system Hazards analysis report E-mail alerts / memos from FSAI or EU Management review documentation Scientific Papers Staff training records
During internal audits quarterly Once / year Or After changes Once / year Or After changes Once / year Or After changes Once / Year Once / Year Or on induction of new / contract staff
Internal auditor & Technical Manager HACCP Team HACCP Team Technical Manager HACCP team HR
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Potential Hazard Hepatitis A, Salmonella, E. Coli, E. coli 0157:H7 Listeria monocytogenes Campylobacter jejuni Shigella, Other food poisoning organisms Norwalk Viruses Parasites i.e. Cyclosporidium Salmonella Pesticides
Critical Limits Elimination of poor hygiene practices By food handlers etc Poor hygiene practices Poor cleaning practices
References Code of Hygienic Practices for Fresh Fruit & Vegetables (Codex Alimentarius) CACP/RCP53-2003 Customers codes of practice
Sampling plan on microbiological criteria for foodstuffs Control of MRL (pesticide) levels in fruit
Commission Regulation (EC) No: 2073/2005 15th November 2005 Commission Regulation (EC) No: 396/2005 23rd February 2005
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