HACCP HACCP IMPLEMENTATIN ON JUICE PRODUCTION CHAIN

2012

Submitted To:

SIR ABDUL

HARIS

GROUP # 1

“MEMBERS” SEMESTER V (REGULAR)

BS-FST

INSTITUTE OF FOOD SCIENCE AND NUTRITION, UOS.

Alia

20

Surraya

50

Nazish

40 Anam

25

Ishrat

35

Javeria

37

Maria

39

Amna

18

CONTENTS: 1. What is haccp?

2. About haccp

i. History

ii. Need for haccp

3. Objectives of application the haccp

system

4. Preliminary steps

5. HACCP-7 key principles

6. FINALLY DONE :D

What is HACCP?

Have A Cup of Coffee & Pray??? (Dr. Jeannie Sneed, Iowa State)

NO ;) it means…

Hazard

Analysis

Critical

Control

Points

It’s a big name, that seems to be scaring a lot of people, but what it

means to us in Food Service is…

A food safety program that must be based on HACCP

guidelines.

A properly designed and monitored system that ensures

the products we serve and the preparation, storage and holding of

those products is done in the safest possible way.

HACCP (Hazard Analysis Critical Control Point) is the systematic

preventative approach to food safety.

It addresses physical, chemical, and biological hazards as a means of

prevention rather than finished product inspection.

This approach has significant benefits to organizations operating

within the food supply chain as it enables them to determine key

controls over processes and concentrate resources on activities that are

critical to ensuring safe food.

Hazard:

“Danger to health”

Analysis:

“Thorough study/analyze”

Critical:

“Of crucial importance”

Control:

“Handling of conditions”

Points:

“Steps/positions in the process”

First works,

wanted to produce food for

astronauts for guaranty food safety with zero false programs to eat.

issued Haccp

principles in Codex Alimentations.

1973: NASA, Natick American Army laboratory and

prigged common project for astronauts

in food production with zero false and HACCP concept entered to

literature.

1985: USA national science academy suggested that

HACCP should be applied in food operations for food safety.

14 June 1993: HACCP entered to regulations of Europe

Community Countries with directives ‘’Hygiene of food

matters’’

1996: It was all food industry as

HACCP became mandatory in Turkey the date of 16 .11. 1997

with Turkish food codex in food industry.

(Formal newspaper issued the date of 09.06.1998 in ‘’ food production

and audit regulations’’ that HACCP system should be applied. HACCP

was mandatory with same regulation in meat, milk water products,

meat product and milk product producing companies the date of

15.11.2002 after as graduate.)

20 February 1998: Denmark issued DS 3027/1998 HACCP

standard.

3 March 2003: TS 13001/Mart 2003 HACCP standard was issued

“According to HACCP food safety management- regulations related

management system for food producing organization and suppliers’’.

“Food safety management system-

requirements for organizations in food chain’’.

Entrepreneurs must use an HACCP system or a food safety system

It provides a defense for us, against complaints and legal action.

It focuses on food and places the responsibility on Food Service

Employees to serve safe food to the guests.

It raises our professionalism to the next level.

HACCP is a good thing, it’s a preventative program!!

Reduction of

Costs

Of food analysis

Reduction of

Losses due to

Product recall

More efficient

QA

system

Protection of reputation

Prevention of foodborne illness

Preliminary steps:

Assemble the HACCP team:

The HACCP team must be composed of individuals with specific

knowledge of the product manufacturing, its characteristics, its

variability, limitations and distributions.

The HACCP team is generally comprised of:

Electrical engineer

Sanitarian

Microbiologist

Production manager

Quality assurance manager

Distributer

Marketer

Description of product:

It includes the overall description of the product including its

characterization, ingredients, processing methods, packaging and

storage requirements etc.

FOR EXAMPLE:

For juice production, major ingredients involved are:

Fruit

Water

Sugar

Minor ingredients (permissible food additives)

It’s packed in either polypropylene bottles or tetra packs. And it’s stored

at 40°F.

Identification of intended use:

Juice is commonly used in Pakistan as instant energy source. Also used

in breakfast.

Development of flow diagram:

RAW MATERIAL

(selection of fruits)

Sorting and Grading

Washing

(Sanitization & rinsing)

Extraction

Filtration

Pasteurization

Cooling

Aseptic filling &

packaging

Storage

Onset confirmation of flow diagram:

The HACCP team goes on the site to have an onsite review of the

manufacturing operation to verify the accuracy and completeness of the

flow diagram.

Hazard analysis is a process of collecting information on hazards and

conditions leading to their presence to decide which are significant for

food safety and should be addressed in HACCP plan.

HAZARDS

Physical hazards:

Foreign matter unintentionally

introduced to food.

Chemical hazards:

are risks to food safety caused by

contamination of chemical substances

Biological hazards:

Referred to micro-organisms causing

food borne illness

Steps

Physical hazards Biological hazards Chemical hazards

1-RAW

MATERIAL

Dirt, dust

Immature

fruits

Enzymatic

browning

Patulin(myc

otoxin)

Pesticides

Vegetative

and

protozoan

pathogens

Insects and

rodents

HAZARDS

2-SORTING &

GRADING

-Contamination

from operator &

production

environment

-rotten fruits

----- Pathogenic

/spoilage

3-WASHING ----- Chemicals

&

pesticides

Microbiolo

gical

contaminat

ion during

process

4-

EXTRACTION

Metal

fragments

Cross

contaminat

ion

Rust

Grease &

oil

Pathogens

5-

FILTRATION ---- ----

Cross

contaminat

ion

6-

Pasteurizatio

n

Time &

temp.

fluctuation

Patulin ----

7-ASEPTIC

FILLING &

PACKAGING

Un-

sterilized

cans

Dirty

packaging

material

Acrylonitril

e

Off-flavors

Flies &

mosquitoes

8-COOLING Time &

temp.

fluctuation ---- Microbial

growth

9-STORAGE Temp.

fluctuation pH change

Mold

growth

2- IDENTIFICATION OF CCPs:

Critical Control Point (CCP) is a point, step or procedure at which

controls can be applied and a food safety hazard can be prevented,

eliminated or reduced to acceptable (critical) levels.

STEPS MAJOR HAZARDS Are these severe

hazards? CCP

mentioned?

RAW MATERIAL Enzymatic

browning

Immature fruits

SORTING &

GRADING

Pathogens/

spoilage

Patulin

WASHING Pesticides

Microbial contamination

Patulin

EXTRACTION Cross contamination

Rust & grease

pathogens

FILTRATION Cross

contamination

Patulin

PASTEURIZATIN Time & temp.

fluctuation

Patulin

PASTEURIZATIN Time & temp.

fluctuation

Patulin

ASEPTIC FILLING &

PACKAGING

Microbial

contamination

Time & temp

STORAGE Microbiological

contamination

PROCESSING

STEPS Critical limits

SORTING AND

GRADING Grading-fruit rejection standards.

WASHING Proper procedures for washing.

EXTRACTION Clean & sanitized equipment.

Prevent overhead contamination.

PASTEURIZATION Specified time & temperature.

COOLING Cool at should be 40°F

STORAGE Maintain at 40°F or below

4-establish monitoring procedures:

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.

PROCESSING

STEPS MONITORING PROCEDURES

SORTING &

GRADING Visual inspection

WASHING 200 ppm chlorine/equiv. rinsing per each use

EXTRACTION Visual inspection/observation of

equipment daily

PASTEURIZATION

COOLING Temperature recordings/hourly

STORAGE Temperature checks

5-establish corrective action:

Procedures followed when a deviation occurs.

6-Establish procedures for verification:

Those activities, other than monitoring, that determine the validity of

the HACCP plan and that the system is operating according to the plan.

These processes should take place during the development and

implementation of the HACCP plans and maintenance of the HACCP

system. One aspect of verification is evaluating whether the facility's

HACCP system is functioning according to the HACCP plan. An effective

PROCESSING

STEPS

CORRECTIVE ACTIONS

SORTING &

GRADING

Re-grade or reject

WASHING Re-wash

EXTRACTION Stock production

PASTEURIZATION Stop production & clean properly

COOLING Cool to 40°F

STORAGE Cool to 40°F

HACCP system requires little end-product testing, since sufficient

validated safeguards are built in early in the process. Therefore, rather

than relying on end-product testing, firms should rely on frequent

reviews of their HACCP plan, verification that the HACCP plan is

being correctly followed, and review of CCP monitoring and corrective

action records.

Activity Frequency Responsibility Reviewer Verification Activities Scheduling

Yearly or Upon HACCP System Change

HACCP Coordinator Plant Manager

Initial Validation of HACCP Plan

Prior to and During Initial Implementation of Plan

Independent Expert(s)(a) HACCP Team

Subsequent validation of HACCP Plan

When Critical Limits Changed, Significant Changes in Process, Equipment Changed, After System Failure, etc.

Independent Expert(s)(a) HACCP Team

Verification of CCP Monitoring as Described in the Plan (e.g., monitoring of patty cooking temperature)

According to HACCP Plan (e.g., once per shift)

According to HACCP Plan (e.g., Line Supervisor)

According to HACCP Plan (e.g., Quality Control)

Review of Monitoring, Corrective Action Records to Show Compliance with the Plan

Monthly Quality Assurance HACCP Team

Comprehensive HACCP System Verification

Yearly Independent Expert(s)(a) Plant Manager

Generally, the records maintained for the HACCP System should

include the following:

1. A summary of the hazard analysis, including the rationale

for determining hazards and control measures.

2. The HACCP Plan

Listing of the HACCP team and assigned responsibilities.

Description of the food, its distribution, intended use, and

consumer.

Verified flow diagram.

HACCP Plan Summary Table that includes information for:

Steps in the process that are CCPs

The hazard(s) of concern.

Critical limits

Monitoring*

Corrective actions*

Verification procedures and schedule*

Record-keeping procedures*

A brief summary of position responsible for performing the activity

and the procedures and frequency should be provided.

The following is an example of a HACCP plan summary table:

CCP Hazards Critical

limit(s)

Monitoring Corrective

Actions

Verification Records

4. Support documentation such as validation records.

5. Records that are generated during the operation of the plan.

HACCP

IMPLEMENTED