IMPLEMENTATION OF HAZARD ANALYSIS CRITICAL CONTROL

POINT (HACCP) SYSTEM TO THE ALCOHOLIC BEVERAGE

INDUSTRY

Submitted by:

Abhishek Rana

Amber Awasthi

Ankita Pathania

Charul Sharma

Deepak Dhar

Devansh Jaiswal

INTRODUCTION

• Real target- minimization of unacceptable unsafe products

• Prior to initiating HACCP system, company must endeavor to put together HACCP plan :

a) identify HACCP resources & assemble team b) describe food & its distribution method c) state clearly intended use & consumers d) develop a process flow diagram e) verify validity of this diagram in practice (operation)• 2 most important stages- Fermentation & bottling

HACCP Team

Names of members

Titles/responsibilities Educational qualification

Experience or training

Abhishek Rana Clean up/sanitation B. Tech (FST) _

Amber Awasthi Outside Expert B. Tech (FST) _

Ankita Pathania Laboratory, Quality Assurance

B. Tech (FST) _

Charul Sharma Plant Manager B. Tech (FST) _

Deepak Dhar Production B. Tech (FST) _

Devansh Jaswal Engineer B. Tech (FST) _

Product Description

NAME OF PRODUCT RED WINE

FOOD SAFETY CHARACTERISTICS pH : 3.3-3.5Alcoholic content : 11-15%

PACKAGING USED Glass bottles sealed with cork with final packaging of silver & gold paper ; bag in boxes

LABELLING REQUIREMENTS Alcohol content, sulphite declaration & health warning statement

STORAGE & DISTRIBUTION Store in dark, moderately humid place at 130C

INTENDED CONSUMERS Adults

INTENDED USE Ready to drink, as an ingredient

SHELF LIFE Bottled : 2-3 yearsOpened (refrigerator) : 1-2 weeks

INTENDED USE

•Retail, ingredient, institutional

Intended use

•Adults, elderly

Intended & likely consumers

•Nationwide

Distribution area

•Adults (70%), elderly(20%)

Consumer of food

•Preferably refrigerated (130

C)

Distribution

RED WINE

• Red wine is made from dark-coloured (black) grape varieties

• Actual colour range- intense violet (young wines), brick red (mature wines) & brown (older red wines)

• Juice from most black grapes is greenish-white; red colour comes from anthocyanins present in the skin of the grape

• Red-wine production process involves extraction of colour & flavour components from grape skin.

Plant layout

PROMINENT HAZARDS IDENTIFIED

•Fruit with rotten parts

•Bottle condition

•Cork sizing

PHYSICAL•Pesticide

residues•Heavy metals•Residues of

ethylene glycol & detergents

•Methanol content

•Ethyl carbamate formation

CHEMICAL

•Microbial contamination of culture

•Water microbiological quality

•Presence of yeasts & LAB

•Cork microflora

MICROBIOLOGICAL

CCP-1 (Harvesting)

• Grape harvesting is CCP comprising both physical & chemical hazards• Physically, grapes should be sound without rotten parts, otherwise oxidative &

microbial contamination can rapidly develop• Harvesting should be conducted with greatest possible care & efficient disease

management system should be applied• Pesticides should be handled with care as they constitute chemical hazards.• At time of harvest, the grapes must have also reached correct maturity when Brix

& Total Acidity levels indicate maturity of wine• Pesticide & fungicide residues on surface of berries constitute chemical hazards• Rapid & simple gas chromatography- method for determination• Maximum residue limits for pesticides (grapes & wines)- Codex Alimentarius (45)• Bulk bins used for grapes transportation, should be effectively decontaminated

to avoid any microbial infection

CCP-2 (Alcoholic Fermentation)

• carried out by strains of Saccharomyces cerevisiae - grows at low pH values typical for grape must (pH 3.2–4)

• chemical hazards : heavy metals presence (As<0.2, Cd<0.01, Cu<1, Pb<0.3 mg/L), methanol content (300 mg/L ), ethyl carbamate content, pesticide residues (as mentioned in the Codex Alimentarius) & residues of detergents (absence) & ethylene glycol (absence)

• desirable temperature varies within the range of 25–28◦C

CCP-3 (Must)

• Possible contamination of must with killer yeasts result in stuck fermentation

• Attention should be paid to added amount of SO2

i.e.175mg/L in order to inhibit

CCP-4 (Maturation)

• Maturation step often lasts 6–24 months & takes place in oak barrels• During maturation a range of physical & chemical interactions occurs

among barrel, surrounding atmosphere & maturing wine, leading to transformation of flavor and composition of wine

• Oak barrel should be fault-free & undergone decontamination treatment• Wood must be free of pronounced or undesirable odors, which could taint

the wine• White wines are matured in oak for shorter periods than red wines & in

conditioned barrels to release less extractable (tannins)• Another CCP- inhibition of O2 penetration through wood or during racking

& sampling of wine• Extensive penetration can cause various sensory changes (oxidized odor,

browning, loss of color in red wines, activation of spoilage bacteria & yeasts, development of ferric casse & precipitation of tannins)

CCP-5 (Stabilization)

• Reason for stabilization- production of permanently clear & flavor fault-free wine

• Procedure a) tartrate stabilization by chilling wine to near its freezing point &

filtering or centrifuging to remove crystals b) protein stabilization with absorption, denaturation or neutralization

by fining agents (bentonite) c) polysaccharide removal with pectinases that hydrolyze polymer,

disturbing its protective colloidal action & filter plugging properties d) metal casse (Fe, Cu) stabilization• Ferric casse is controlled by addition of agents (bentonites, proteins)

controlling flocculation of insoluble ferric complexes• Wines with Cu content greater than 0.5 mg/L are particularly

susceptible to Cu casse formation

CCP-6 (Bottling)

• Wine is bottled in glass bottles sealed with cork which must pass a decontaminating step & an inspection control to assure absence of any defects & stability of product until its consumption

• Cork should be correctly sized, 6–7 mm bigger than inner neck diameter, to avoid any possible leaks

• Hazards include : cork microflora, residues of heavy metals, SO2, pesticides & detergents & absence of cracks, scratches & rifts in lute

• CL for cork is absence of LAB & yeast, which can be assured with microbiological analysis

• For long storage of wine longer & denser corks are preferred• Headspace O2 might affect product quality by causing disease of “bottle”

• CL for SO2 – 175mg/L , for As < 0.2 mg/L, Cd < 0.01 mg/L, Cu < 1 mg/L, Pb < 0.3 mg/L

CCP-7 (Storage)

• Shipping & storage of wines at elevated temperatures can initiate rapid changes in color & flavor of wine

• Direct exposure to sunlight corresponds to effect of warm storage temperatures

• Temperature affects reaction rates involved in maturation, such as acceleration of hydrolysis of aromatic esters & loss of terpene fragrances

• Temperature can also affect wine volume & eventually loosen cork seal, leading to leakage, oxidation & possibly microbial formation resulting in spoilage of bottled wine

CRITICAL LIMITS

PROCESS STEPS CRITICAL LIMITS

Harvesting Rotten parts reduced to acceptable levelPer pesticideaccording to Codex Alim.

Fermentation As < 0.2, Cd <0.01, Cu < 1, Pb < 0.3 (mg/L)Pesticide residues according to Codex AlimEthylene glycol & detergent residues Absent in 300 mg/L

Must 100% clean

Maturation Absence of yeasts, molds and LAB

Stablization As < 0.2, Cd <0.01, Cu < 1, Pb < 0.3 (mg/L)

Bottling As < 0.2, Cd <0.01, Cu < 1, Pb< 0.3 (mg/L)Pesticide residues according to Codex AlimAbsence of rifts in lute, cracks, scratchesYeast, LAB absence

Storage wine quality as set by each plant

MONITORING PROCEDURES FOLLOWED

• Harvesting: Inspection during harvesting, Specific chemical analyses

• Fermentation: Specific chemical analyses, Gas chromatography

• Must: Microbiological analyses• Maturation: Microbiological analyses• Stabilization: Specific chemical analyses• Bottling: Specific chemical analyses, Visual inspection,

Sample measurements, Microbiological analyses• Storage: Organoleptic controls

CORRECTIVE ACTIONS APPLIED

• Fermentation- Rejection of specific batch, dilution with large quantities, machinery modification

• Bottling- Modification of CIP, Disinfect area, rejection of faulty bottles

• Storage- Rejection of faulty batches

THANK YOU