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HACCP Generic Model for
Pineapple Jam
Introduction to “Freshtz”
Located in Industrial Zone, Ja-ela
15 years of history
Over 400 employees
Specialized in Fruit processing
Pineapple jam is the main product
Our Mission
Serve the local suppliers and our customers through engaging in reasonable business
Providing high quality product
Our Vision
To be a pioneer nutritive, safe and high quality, Jam
producer in Sri Laka
Why we need HACCP
Improve the safety of our products
Achieve our long term goals
Reduce wastage
Reduce cost of production
Increase consumer confidence
Develop company Brand
Hazard Analysis and Critical Control Point(HACCP) is an internationally recognizedsystem for reducing the risk of safety hazardsin food.
Implementing a HACCP System requires
Prerequisite Programs
HACCP Plans
WHAT IS HACCP???
con’t
Is a system for food safety and not for the quality
Is a tool to protect against biological, chemical and physical
hazards in the food product
Is designed to minimize, not eliminate, the risk of food safety
hazards
Is designed for each materials and procedures
Receiving and storage
Sanitation of premises and surrounding environment
Personal hygiene of employees
Water supply
Equipment handling and maintenance
Lighting and ventilation
Waste management
Pest control
Pre requisite programs
• Consists of personnel with specific knowledge and expertise with regard to, the product and process
• Members were selected from each part of the pineapple jam plant
• Conducted the necessary studies, supervised the implementation of the HACCP plan and maintained its performance.
HACCP TEAM
HACCP TEAM
Factory Name:- “Freshtz” Product (pvt) Ltd
Team Member Name Position HACCP Team Role
E.M.P.P. Ekanayaka Production executive Coordinator
T.S.M Thilakarathne Quality Executive Member
N.R Nanayakkara Marketing & Finance Executive Member
T.Gawshiga Engineer Member
W.M.K.I.Bandara Fruit reception manager Member
Barathy Muddiyappu Shift leader of cutting, washing & peeling
Member
M.Chageethana Shift leader of production & packaging
Member
Shashindhi Samarakoon Cleaning supervisor Member
Pabodha Kodagoda Labour Member
T.Thadshayani SLSI consultant Advisor
Full descriptions of the pineapple jam
• Important product characteristics - aw, pH, colour
• Ingredients-pineapple, sugar, pectin, citric acid, water
• How is product used - With bakery products as spread
• Packaging - In sterilized glass jars
• Shelf life - 8 months
• Where will product be sold-Super markets , retail shop
• Labeling instructions
• Special distribution control
Product details & its distribution
General consumer – All age groups except
children less than 5 years
Food industry – Hotels, Fast food outlets
Not recommended for the people with
diabetics
Intended use & consumers
Flow diagram for pineapple jams production
1. Perform a Hazard Analysis
2. Determine Critical Control Points
3. Determine the Critical Limits
4. Monitoring Procedures of CCPs
5. Corrective Actions
6. Verification Procedures
7. Record Keeping Procedures
The 7 HACCP Principles
The process of collecting and evaluating information on
biological hazards
chemical hazards
physical hazards
associated with the flow of the Jam production process
Hazard Analysis
Biological Hazards – bacteria like Salmonella spp,
E. coli, Clostridium perfringens,Staphylococcus aureus, Vibriocholerae, Yeast & Mold
Chemical Hazards –Herbicide, Nitrate,polyurethane resin, chlorine,Lubricant, Heavy metals in inkHg, Cr, chlorine
Physical Hazards –Sand, Wood, Rotten fruits,Stones, Leaves, Metal fragments,Glass particles
Hazard Analysis cont'd
Done for
Ingredients,
raw materials,
step in the process,
product storage ,
Distribution,
Hazard Analysis cont'd
This is a point where Biological contaminationChemical contaminationPhysical contamination
can occur where loss of control may result in unacceptable health risk.
These hazards will be eliminatedprevented reduced
to an acceptable level at each step in the jam production process
Critical Control Points
Decision tree Model
Critical Control Points cont'd
The boundaries that must be met to control a food safety hazard
These standards will be
Observable
Measurable
usually specified by using temperature and time
Critical Limits
All CCPs are used
a maximum or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent to an acceptable level
Ex: temperature, time, visual appearance
Critical Limits cont’d
Critical Control Points, Critical Limits,employees practices,
will be monitored on a daily basis by the employees involved in Jam production
Observations will be made to compare what actually happens to the standards that have been established.
Monitoring Procedures of CCPs
Established if a Critical Limit has not been met at a Critical Control Point
It will address what needs to be done to eliminate or control the possible hazards
Corrective Action
Process/St
ep CCP
Hazard(s) Critical
Limit
Monitoring Procedure Corrective
ActionsWhat How Frequency Who
CCP # 1
Sterilization
of glass
bottles (P)
Broken Glass
particles
No
damaged
bottles
Damaged
bottles
Visual
observation
Every bottle Worker at
Sterilizatio
n machine
Remove the
damaged
bottle and
send to the
glass
recycling
CCP # 2
Pasteurizatio
n (B)
Clostridium
perfringens
0cfu/ml
Clostridium
perfringens
Pasteuriza
tion time
and
temperatu
re
Visual
observation
Once the
alarm of the
machine
sounds
Worker at
Pasteuriza
tion
machine
Hold the
pasteurizatio
n.
Call the
quality
assurance
executive.
Verification may be defined as activities other than monitoring, that determine validity of HACCP
Primary components
Critical control point verification.
HACCP system verification.
Validation.
Verification
Critical control point verificationCCP is backbone of the HACCPimportant to verified the all activities and procedures
HACCP system verificationit contains, activities that go beyond the written plan to it’s implementation
Validation collecting and evaluating scientific and technical information to determine whether HACCP is properly implemented
Verification cont’d
Important aspects
Check whether HACCP system is functioning according to written HACCP procedure
Initial validation of HACCP plan to determine that it is scientifically and technically tested
Verification procedure can be carried out by individuals within a company for each CCP
Verification cont’d
It is a process to maintain written documents for each verification procedure.
2 CCPs – 1. sterilization of glass bottles
There would be glass particles in machine-cause hazard.
2. pasteurization
There would be microbes called clostridium perfringens in
pasteurization machine- cause hazard.
Machine operation log is checked and commented on log book.
Record keeping
Process Step/CCP Verification Procedure Records
CCP# 1
Sterilization of glass
bottles (P)
Check the machine
operation log every day
comments on log book
CCP # 2
Pasteurization (B)
Check the machine
operation log every day
comments on log book
Introduction
What is HACCP?
Pre requisite programs
The 7 HACCP Principles 7 HACCP Principles
Summary