Upload
others
View
5
Download
0
Embed Size (px)
Citation preview
HACCP PLAN Soy-Based Sauce Production (Sos Rojak Buah)
Sem. 2, 2017/2018
NAME MATRIC NO
Farah Adleen Zakaria 189451
Suganthi D/O Selvadurai 189563
Nurelyzurina Sukri 190103
Nor Farzana Mohd Razali 190265
Muhammad Muhsin Mohamed Makki 190510
INTRODUCTION
This case study included:
The preliminary of HACCP – list out the product description & the process flow diagram
The disadvantages of the current production & the improvement
Based on the improvement :-
identify hazard analysis + critical control points (CCPs) Specify the critical limits Described approciate monitoring activites for each CCPs Design the corrective ction for each CCPs & how will it will
be reviewed in the future.
OBJECTIVES
• Execute all the seven main principles of the Codex Alimentations approach to
HACCP.
• Determine the appropriate level detail that is needed in HACCP plan.
• Understand how using HACCP helps to achieve Quality Assurance.
• Appreciate other benefits of HACCP system.
HACCP TEAM
Muhammad Muhsin Mohammed Makki
Production operator
Nor Farzana MohdRazali
Food technology
Farah Adleen Zakaria
Quality assurance
Suganthi A/P Selvadurai
Hygiene manager
Nurelyzurina Sukri
Maintenance
PRODUCT DESCRIPTION
1. Product name Sos Rojak Buah
2. Type of product Ready-to-eat
3. Shelf-life of the product under proper
storage conditions
9 months at room
temperature
4. Raw materials shrimps paste, sweet soy
sauce, sugar, salt, sesame
and chili powder.
CURRENT FLOW CHART
CURRENT PRODUCTION PROCESSES AND IMPROVEMENT
• Did not have a proper place for storage and process as they made the sauce inside their house
• Food packaging did not have expired date and nutritional table for the reference for the consumer
• The finished product was stored at ambient temperature
• Use full manual system will results in low productivity
Disadvantage of
Current Process
IMPROVED FLOW CHART
Improvement suggestion based on pre-requisite program (PRP) knowledge
1. Training
- To create awareness among employees on GMP.
2. Standard Operation Procedure (SOP)
- Ensure consistency in daily operations. Simple, detailed, written.
3. Industry Design – Ventilation
- Protect air quality/odor/temperature/humidity.
4. Good Hygiene Practice (GHP)
- Provide a clean sanitary environment for every process.
5. Personal Hygiene
- Health status and personal cleanliness
HAZARD EVALUATION
Process
Step
Potential Hazards Likelihood Severity Risk
factor
Is this a signification
hazard?
What measures can be applied
to control this significant hazard
Cooking B Clostridium perfringens
Clostridium botulinum
Salmonella
3 6 18 Yes Ensure adequate cooking
C Sanitizer residue 2 4 8 Yes Minimize usage of sanitizer
P Foreign materials 2 4 8 Yes Install detection and
elimination system
Hot filling B Clostridium perfringens
Clostridium botulinum
Salmonella
3 6 18 Yes Maintain the temperature of
hot filling
C None identified
P Foreign materials 2 4 8 Yes Install detection and
elimination system
Process
Step
Potential Hazards Likelihood Severity Risk factor Is this a
signification
hazard?
What measures can
be applied to
control this
significant hazard
Capping B Clostridium
perfringens
Clostridium
botulinum
Salmonella
3 6 18 Yes Capping quickly to
prevent pathogens
growth
C None identified
P Foreign materials 2 4 8 Yes Install detection and
elimination system
CRITICAL CONTROL POINTS (CCP)
Process step in the food processing where a food hazard can be prevented, eliminated or reduced to an
acceptable level
CODEX
DECISION TREE
Process
Step
Potential Hazards Q1: Are there
control
measure(s) for the
significant
hazard?
Q2: Is the process
step specifically
designed to
eliminate or
reduce the likely
occurrence of the
significant hazard
to an acceptable
level?
Q3: Could
contamination
occur at
unacceptable
level or increase
to
unacceptable
level ?
Q4: Will a
subsequent
process step
eliminate or
reduce the
significant
hazard to an
acceptable level?
Is this
Critical
Control Point
(CCP)
Cooking B • Clostridium
perfringens
• Clostridium
botulinum
• Salmonella
Yes
Adequate cooking
eliminate the
pathogens
presence
Yes
Cooking can kill
Clostridium and
salmonella
CCP-1
C Sanitizer residue Yes
use of sanitizer according to manufacturer’s instruction
No
cooking is not to eliminate sanitizer residue
Yes
High sanitizer residue can lead to health problem to consumer
No
Other process
cannot eliminate
this hazard to
acceptable level
CCP-1
P Foreign materials Yes
Install detection and elimination system
No
Cooking is not a process to eliminate foreign materials
Yes Food contamination may occur
No
Other process
cannot eliminate
this hazard to
acceptable level
CCP-1
Process
Step
Potential Hazards Q1: Are there
control
measure(s) for the
significant
hazard?
Q2: Is the
process step
specifically
designed to
eliminate or
reduce the likely
occurrence of
the significant
hazard to an
acceptable level?
Q3: Could
contamination
occur at
unacceptable level
or increase to
unacceptable level
Q4: Will a
subsequent
process step
eliminate or
reduce the
significant
hazard to an
acceptable level?
Is this
Critical
Control Point
(CCP)
Hot filling B Clostridium
perfringens
Clostridium
botulinum
Salmonella
Yes
Maintain the
temperature of
hot filling
eliminate the
pathogens
presence
Yes
Hot filling can kill
Clostridium and
salmonella
CCP-2
C None identified
P Foreign materials Yes
Install detection and elimination system
No
Hot filling is not a process to eliminate foreign materials
Yes Food contamination may occur
No
Other process
cannot eliminate
this hazard to
acceptable level
CCP-2
Process
Step
Potential Hazards Q1: Are there
control
measure(s) for
the significant
hazard?
Q2: Is the process
step specifically
designed to
eliminate or
reduce the likely
occurrence of the
significant
hazard to an
acceptable level?
Q3: Could
contamination
occur at
unacceptable
level or increase
to
unacceptable
level
Q4: Will a
subsequent
process step
eliminate or
reduce the
significant
hazard to an
acceptable level?
Is this
Critical
Control
Point
(CCP)
Capping B Clostridium
perfringens
Clostridium
botulinum
Salmonella
Yes
Maintain the
temperature of
product to
eliminate the
pathogens
presence
Yes
Capping can kill
clostridium and
salmonella
CCP-3
C None identified
P Foreign materials Yes
Install detection and elimination system
No
Capping is not a process to eliminate foreign materials
Yes Food contamination may occur
No
Other process
cannot eliminate
this hazard to
acceptable level
CCP-3
CRITICAL LIMITS
Maximum or minimum value to which a biological, chemical or physical parameter must be controlled at a
CCP to prevent, eliminate or reduce to an acceptable level for the occurrence of a food safety hazard
Process Step Potential Hazard Critical Limits
CCP-1
Cooking (B)
Clostridium perfringens
Clostridium botulinum
Salmonella
Ensure cooking temperature
above 73oC
CCP-2
Hot filling (B)
Clostridium perfringens
Clostridium botulinum
Salmonella
Maintain hot filling
temperature above 60oC
CCP-3
Capping (B)
Clostridium perfringens
Clostridium botulinum
Salmonella
Ensure the cap is fit with the
plastic bottle and check the
integrity of the cap to prevent
any damage
MONITORING ACTIVITIESMonitor is to conduct a planned sequence of observations or measurements to assess whether a CCP is under control
and to produce an accurate record for future use in verification
CORRECTIVE ACTION
Procedures followed when the monitoring result show that a critical points derivates from the critical limits.
CCP and
Process
Monitoring procedures Corrective action
CCP-1
Cooking
• Measure the product’s internal
temperature. These temperature
readings must be taken each time a
batch of sauce is cooked.
• Calibrate the thermometer to ensure it
is working correctly before measuring
the product’s internal temperature.
• Record the results on the “Sauce
Cooking Record,” including the date, the
time, and initials.
• Causes of the deviation will be identified
and eliminated
• Measures all the associated paramaters
to prevent recurrence of the hazards
CCP and
Process
Monitoring procedures Corrective action
CCP-2
Hot filling
• Operator’s must ensure the
temperature of cooked sauce above
60oC to prevent contamination and
growth of pathogen occur.
• Install thermometer alarms that display
the current temperature. If the
temperature reached room
temperature that operator fixed, the
alarm will trigger.
• Recook the product
• Separate and hold the product for a
safety evaluation.
• Adjust the cooking equipment to
increase the processing temperature
CCP and
Process
Monitoring procedures Corrective action
CCP-3
Capping
• The environment of bottling and
capping need to ensure clean and dry to
prevent cross contamination.
• Workers hygiene ensured before
packaging process starts.
• Swab table tops, packaging surfaces,
workers gloves, aprons, etc., that make
contact with exposed cooked product.
• Manager/ supervisor must always
check whether workers follow the SOP.
• Divert the product to a use in which the
critical limit is not applicable (e.g.,
divert to others operation).
• Identify and correct the source of the
defect.
CONCLUSION
• The improvement that have been proposed are to increase the quality of the product (ex: shelf life :12months) and its potential to be widen in the market.
• Some steps are proposed such as preparing the raw materials, hot filling, capping, labelling and chill storage to improve the product so that it will be consumed by more people and also to eliminate several potential hazards along the production process.
• Moreover, to make sure the product is been qualified to be widen in the market. Thus, the valid licensed food businesses is needed by proposing this HACCP.
THANK YOU