final assignment product design

UNIVERSITAS INDONESIA

SYNTHETIC CHICKEN MEAT

Report Assignment 5

GROUP 30

GROUP PERSONNEL: AISYAH NUR RIDHA (1306481991)

BUDI MULIA PANGGABEAN (1206220586)

ERIC ADELWIN (1206263326)

HUSNUL FAJRI (1206224994)

PARAMITA DONA FITRIA (1206263383)

CHEMICAL ENGINEERING DEPARTMENT

E N G I N E E R I N G F A C U L T Y

UNIVERSITAS INDONESIA

DEPOK

2015

ii Univeristas Indonesia

EXECUTIVE SUMMARY

In this chapter, we will explain about the health and safety analysis of our

product, HEMAT synthetic chicken meat. First, we will explain about the

hazard analysis method which we used in our factory product. After that, we will

explain the Material Safety Data Sheet (MSDS) of our product raw material. The

Material Safety Data Sheet (MSDS) itself is a a document that contains

information on the potential hazards (health, fire, reactivity and environmental)

and how to work safely with the chemical product. Our raw material such as

mushroom, flavor enhancer, sugar, salt, egg, etc will be explained each of their

MSDS.

The method itself which we used in hazard analysis called Hazard

Identification and Risk Assessment (HIRA). HIRA is a sheet that contains an

analysis of the prevention of hazards in an industrial plant or factory based on

aspects and activities in it.

We also need to do performance test to know how good is our product.

Performance test is the resistance of a product to the manufacturer to know

anything just things that can damage or reduce the quality of the product. Safety

of food products associated with the expiration date of the product, microbial

growth and contamination with chemicals or metals need to pass the maximum

limit for human health. To determine the factors that reduce the quality of our

food products is a way to test that is testing of microbial contamination, testing for

contamination from chemical compounds such as metal and testing of temperature

to determine how long the food product can survive.

Finally we need to tell the GHS of our product. GHS identify the

hazardous properties of chemicals that may pose a health, physical or

environmental hazard during normal handling or use. The goal of the GHS is to

identify the intrinsic hazards found in chemical substances and mixtures, and to

convey information about these hazards.

iii Univeristas Indonesia

Table of Content

EXECUTIVE SUMMARY.................................................................................... i

CHAPTER 1 ANALYSIS OF HEALTH AND SAFETY Error! Bookmark not

defined.

1.1. Hazard Analysis ........................................ Error! Bookmark not defined.

1.1.1. MSDS (Material Safety Data Sheet) Analysis.................................... 12

1.1.1.1. Sugar ................................................................................................... 2

1.1.1.2. Osyter Mushroom ............................................................................... 3

1.1.1.3. Salt ...................................................................................................... 4

1.1.1.4. Flavor Enhancer .................................................................................. 4

1.1.1.5. Flour .................................................................................................... 4

1.1.1.6. Egg ...................................................................................................... 5

1.1.1.7. Garlic .................................................................................................. 5

1.1.1.8. Peanut ................................................................................................. 5

1.1.1.9. Red Onion ........................................................................................... 6

1.1.1.10. LDPE ................................................................................................ 6

1.1.1.11. Cardboard ......................................................................................... 6

1.1.2. HIRA (Hazard Identification and Risk Assessment) ............................ 7

1.2. Waste Treatment ...................................................................................... 12

1.2.1. Mushroom and Garlic Waste ............... Error! Bookmark not defined.

1.2.2. Mushroom and Garlic Wash Water ..... Error! Bookmark not defined.

1.2.3. Equipment Sanitation Water ................ Error! Bookmark not defined.

1.3. Regulation ................................................................................................. 15

1.3.1. Performance Test ................................................................................ 17

1.3.1.1. Microbial Contamination Test Method ............................................ 17

1.3.1.2. Testing of metal contamination in the food with AAS ..................... 18

1.3.1.3. Method of determining the shelf life of food products ..................... 19

1.4. Hazard Communication .......................................................................... 21

1.4.1. Food Allergen Icons ........................................................................... 21

1.4.1. Food Safety Icons ............................................................................... 23

CHAPTER 2 CONCLUSION ............................................................................ 26

iv Univeristas Indonesia

REFERENCES ..................................................................................................... 27

APPENDICES ...................................................................................................... 28

v Univeristas Indonesia

List of Table

Table 1.1 Raw material composition .................................................................................. 2

Table 1.2 Parameter in calculating hazard possibility ........................................................ 8

Table 1.3 Parameter in calculating hazard effect ................................................................ 8

Table 1.4 HIRA of HEMAT factory ................................................................................... 9

Table 1.5 BPOM regulation for limit of microbial ........................................................... 15

Table 1.6 SNI for chicken nugget ..................................................................................... 15

Table 1.7 Maximum limit of microbial contamination ..................................................... 18

Table 1.8 High quality life in temperature varians ........................................................... 21

vi Univeristas Indonesia

List of Figure

Figure 1.1 Plant Layout ................................................................................................... 11

Figure 1.2 Wash Water Purification in Vegetable Processing ......................................... 13

Figure 1.3 Food Allergy Warning .................................................................................... 22

Figure 1.4 Food Allergy Warning of Gluten ................................................................... 23

Figure 1.5 Safe Food Handling ........................................................................................ 23

Figure 1.6 Cooking Method ............................................................................................. 24

Figure 1.7 Potentially Hazardous Materials ..................................................................... 24

Figure 1.8 Products Packaging ....................................................................................... 25

1 Universitas Indonesia

CHAPTER 1

ANALYSYS HEALTH AND SAFETY

HSE is a management system that the company's management systems are

intended to be used as a guide in the implementation of the management system

which can simultaneously accommodate HSE eligibility Management System

based on Occupational Safety and Health Permenaker No. 05/MEN/1996 on

'Application of SMK3 in the Workplace'. Guidelines mainly contains the

company's policy, as a proof of the commitment and responsibility of

management to attempt to guarantee K3, in order to improve the safety and health

protection of workers, corporate guests, partners the company's work, the

protection of corporate assets, and compliance with laws and regulations related to

SMK3.

Safety analysis includes several things, they are availability sheet MSDS

(Material Safety Data Sheets) on the properties and physic-chemical properties of

raw materials, auxiliary materials, or supporting materials the production process

used. Aside from the safety analysis is also the Safety Assessment sheet covering

sheet Hazard Identification (HAZID).

1.1. Hazard Analysis

To reduce the number of deaths, injuries and occupational diseases, in

addition to implementing the global strategy on both the K3, the authors also

conducted a hazard analysis that includes MSDS analysis and Hazard

Identification and Risk Assessment (HIRA).

1.1.1. MSDS (Material Safety Data Sheet) Analysis

A Material Safety Data Sheet (MSDS) is a document that contains

information on the potential hazards (health, fire, reactivity and environmental)

and how to work safely with the chemical product. It is an essential starting point

for the development of a complete health and safety program. It also contains

information on the use, storage, handling and emergency procedures all related to

the hazards of the material. The MSDS contains much more information about the

material than the label. MSDSs are prepared by the supplier or manufacturer of

the material. It is intended to tell what the hazards of the product are, how to use

2

Universitas Indonesia

the product safely, what to expect if the recommendations are not followed, what

to do if accidents occur, how to recognize symptoms of overexposure, and what to

do if such incidents occur.MSDS formats can vary from source to source within a

country depending on national requirements.

SDSs are a widely used system for cataloging information on chemicals,

chemical compounds, and chemical mixtures. SDS information may include

instructions for the safe use and potential hazards associated with a particular

material or product. These data sheets can be found anywhere where chemicals

are being used.

MSDS's provide information on:

the manufacturer or importing supplier

the product (e.g. its name, ingredients and properties)

how the product can affect your health

precautions for using or storing it safely

The MSDS from every raw material is attached in the appendix section, in

this section, MSDS composition will be explained. These table below provides the

composition of raw material of HeMat synthetic chicken meat .

Table 1.1 Raw material composition

Raw Material Comp. (%)

Oyster Mushroom 15

Flour 50

Garlic 2,7

Peanut 5

Red Onion 2,7

Sugar 0,59

Salt 0,5

Egg 3

Flavor Enhancer 0,5 Source: Group 30 discussion

1.1.1.1 Sugar

In making our product, we use the white sugar as one of the several raw

materials. As we can see in the MSDS composition table of white sugar, the

composition of white sugar is 99% sucrose and its composition contain 0.59 %

and it will be estimated in 0.6 % of sugar. So, They are carbohydrates, composed

3


of carbon, hydrogen, and oxygen. There are various types of sugar derived from

different sources. Simple sugars are called monosaccharides and include glucose

(also known as dextrose), fructose and galactose. The table or granulated sugar

most customarily used as food is sucrose, a disaccharide. (In the body, sucrose

hydrolyses into fructose and glucose.) Other disaccharides include maltose and

lactose. Longer chains of sugars are called oligosaccharides. Chemically-different

substances may also have a sweet taste, but are not classified as sugars. Some are

used as lower-calorie food substitutes for sugar described as artificial sweeteners.

White sugar is non-hazardous substance and non-dangerous goods because as we

can see in chemwatch hazard ratings, white sugar only has flammability and body

contact with score one. So, the other aspect like toxicity, reactivity and chronic

has score zero. In the storage requirements for keeping white sugar, is has to keep

in dry, store away from sources of heat or ignition and observe manufactures

storing store under cover, store in well ventilated area, and handling

recommendations.

1.1.1.2. Oyster Mushroom

To emphasize our product is made from natural ingredients and raw

materials, we have decided to use oyster mushroom and the other natural

ingredients in it. Oyster Mushroom composition percentage for the synthetic

chicken meat is estimated in 15 %. Oyster mushrooms health benefits include

antioxidant and anti bacterial properties. Nutrients in these confirm the fact that

mushrooms are chock-a-block full of the good stuff. These mushrooms contain

minerals like zinc, potassium, iron, calcium, phosphorus, and vitamins like B1,

B2, C, folic acid and niacin. Also see properties of Maitake mushroom. Eating

oyster mushrooms regularly ensures that you get your daily quota of these

nutrients, especially that of vitamins. The iron content in these mushrooms is

higher than the iron present in meat a common source for your daily iron. The

potassium in oyster mushrooms is high enough to act as a preventive for heart

disease and hypertension. Mushrooms are known to absorb metals from the soil,

and oyster mushrooms tend to absorb cadmium and mercury. This could present a

health hazard and it would help to know where the mushrooms have originated, in

order to prevent it.

4


Because this raw material is 100% made from natural product, so we can

conclude that the oyster mushroom that we needed can be classified asa and not

reactive and non-hazardous material. For the handling, we must use gloves to

keep the mushroom sterile and away from any contaminants such as bacteria. The

storage requirements for oyster mushroom are store in cool, well ventilated place

protected from light, keep from extreme heat and away from all sources of

ignition.

1.1.1.3. Salt

From the table above, we can see that the composition of salt in HeMat

synthetic chicken meat is estimated in 0.5 %. As we have known that salt consist

of 100% pure sodium chloride. This raw material is non-flammable material, has a

good stability and there is no instability temperature.Slightly hazardous in case of

skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. For the

eye contact, we have to check for and remove any contact lenses. In case of

contact, immediately flush eyes with plenty of water for at least 15 minutes and

Cold water may be used. But this material is reactive with oxidizing agents, metal

and acids. There is no exposure limit for this material, so this material can be

classified as non-hazardous material. The storage requirements for salt are keep

container tightly closed, keep container in a cool, well ventilated area and

hygroscopic.

1.1.1.4. Flavor Enhancer

From the table above, we can see that the composition of flavor enhancer

in HeMat synthetic chicken meat is estimated in 0.5 %. enhancer is non-hazardous

material because flavor enhancer is a non-flammable material, non-reactive

material, non-oral/Parenteral Toxicity, non-dermal toxicity, non-inhalation

toxicity and normally stable even at elevated temperature and pressure. The

storage requirements for flavor enhancer are kept in closed storage, preferably

full, containers away from heat sources and protected from extreme temperature.

1.1.1.5. Flour

From the table above, we can see that the composition of flour in HeMat

synthetic chicken meat is estimated in 50 % or the biggest composition percentage

of raw material percentage This raw material is used for primary packaging for

5


HeMat Synthetic chicken Meat. This material is not corrosive, stable under

normal use conditions for shock, vibration, pressure or temperature and can there

is no irritant effect on the skin and eye but this material is easy to burn. Storage

requirements for flour is in dry storage. protect from heat and direct sunlight, store

container in a well ventilated position, store under dry conditions.

1.1.1.6. Egg

This raw material is used to Create an adhesive and chewy sensation

while consuming the HeMat synthetic chicken meat. From the table above, we can

see that the composition of egg in HeMat synthetic chicken meat is estimated

about 3 %.For the eye contact, we have to check for and remove any contact

lense. This material is not easy to burn, no dangerous substances are released, no

dangerous components and need gloves for contact this material this raw material

has to kept in storage below 8C. There is no special treatment to egg.

1.1.1.7. Garlic

This raw material is used to Create an adhesive and chewy sensation while

consuming the HeMat synthetic chicken meat. From the table above, we can see

that the composition of garlic in HeMat synthetic chicken meat is estimated about

2.7 %. These are raw materials that are easily damaged if just put away. We using

chiller container so that it will inhibit the growth of bacteria to inhibit spoilage.

For we use space cooling (cold room) in the form of container. This container has

termostate which can be adjusted so that the temperature will be suitable for

storage.

1.1.1.8. Peanut

This raw material is used to become one of protein source for the synthetic

chicken meat. Peanut also give some good while consuming the HeMat synthetic

chicken meat. From the table above, we can see that the composition of peanut in

HeMat synthetic chicken meat is estimated about 5 %. These are raw materials

that are easily damaged same as garlic before if just put away. We using chiller

container so that it will inhibit the growth of bacteria to inhibit spoilage. The

storage requirements for peanut are store in cool, well ventilated place protected

from light, keep from extreme heat and away from all sources of ignition.

6


1.1.1.9. Red Onion

This raw material is roled in giving the products taste too.While consuming

the HeMat synthetic chicken meat. From the table above, we can see that the

composition of garlic in HeMat synthetic chicken meat is estimated about 2.7 %.

These are raw materials that are easily damaged if just put away. We use space

cooling (cold room) in the form of container. This container has termostate which

can be adjusted so that the temperature will be suitable for storage. But for the

handling, we must use gloves and goggles because may be irritating for eye and

skin.

1.1.1.10. LDPE (Low-Density PolyEthylene)

This raw material is used for primary packaging for HeMat synthetic chicken

meat. This kind of plastic. LDPE is defined by a density range of 0.9100.940

g/cm3. It is not reactive at room temperatures, except by strong oxidizing agents,

and some solvents cause swelling. It can withstand temperatures of 80 C

continuously and 95 C for a short time. Made in translucent or opaque variations,

it is quite flexible, and tough but breakable. Excellent resistance (no attack / no

chemical reaction) to dilute and concentrated acids, alcohols, bases and esters.

And these are several chemical properties of LDPE:

Good resistance (minor attack / very low chemical reactivity)

to aldehydes, ketones and vegetable oils

Limited resistance (moderate attack / significant chemical reaction,

suitable for short-term use only)

to aliphatic and aromatichydrocarbons, mineral oils, and oxidizing agents

Poor resistance, and not recommended for use with halogenated

hydrocarbons

1.1.1.11. Cardboard

This raw material is used for secondary packaging for HeMat Synthetic

Meat. This material is easy to be burned but no dangerous substances are released,

no dangerous components and no need protection equipment for contact this

material. There is no special treatments to store cardboard, just need temperature

more 4OC.

7


1.1.2. Hazard Identification and Risk Assessment (HIRA)

A HIRA is a risk assessment tool that can be used to assess which hazards

pose the greatest risk in terms of how likely they are to occur and how great their

potential impact may be. It is not intended to be used as a prediction tool to

determine which hazard will cause the next emergency. A HIRA can help to

prepare for the worst and/or most likely hazards, save time by isolating any

hazards which can not affect the community, allow for the creation of emergency

plancs, exercises, and treaining based on the most highest risk scenarios, and the

last is to become proactive rather than just reactive.

There are four steps to create and maintain a HIRA:

1. Hazard Identification - In this step the hazards that could impact your

community are separated from those that cannot. This requires a review of all

hazards and their causes to determine whether they may be a threat to your

community. This may require the consultation of the scientific community,

historical records and government agencies.

2. Risk Assessment - In this step the level of risk for each hazard is examined.

This may involve speaking with hazard experts, researching past occurrences

and possible scenarios. The likelihood of the hazard occurring and the

potential impacts of the hazard on people, property, the environment, business

and finance and critical infrastructure should be examined.

3. Risk Analysis - The information collected in the risk assessment step will be

analyzed in this step. The desired outcome of the risk analysis is the ranking

of the hazards. This highlights the hazards that should be considered a current

priority for your emergency management program.

4. Monitor and Review - It is important to remember that a HIRA is an ongoing

process and hazards and their associated risks must be monitored and

reviewed.

The danger potential and risk identification in HIRA calculates risk level,

countermeasures, and final risk. Risk itself is defined as the combination of hazard

effect and the level of the possibility.

Risk = Hazard Possibility x Hazard Effect

8


The hazard possibility is divided into 3 levels which are high, medium, and low,

so does the hazard effect.

Table 1.2 Parameters in calculating hazard possibility

PARAMETER HIGH MEDIUM LOW

Hazard frequency Everytime the work

done

Once in 10 s/d

100

Only once when

job is done

Hazard effect

frequency

Everytime the work

done

Once in 10 s/d

100

Only once in 100

atau more

Workers

competence

No experience at all in

doing the job before

Less

experienced

Experienced and

Competent Source: Reproduced from brainstorming

Table 1.3 Parameter in calculating the hazard effect

PARAMETER HIGH MEDIUM LOW

Human

Resources

Dead, disability, body

disfunction, trauma,

serious injury

Medium injury,

still can continue

to do work

Light injury

Asset Huge damage towards

the instrumentation,

the production process

stopped

The damage

happened makes

the production

level decreases

Small damage,

didnt affect production level

Protection Tool Protection tool is

nowhere near the

environment where

there are many

flammable materials

Minimum

protection tool

Protection tool is

available, well

isolated and well

installed near the

hazardous area

Evacuation Time Less than a minute Between 1-30

minutes

More than 30

minutes Source: Reproduced from brainstorming

9


10


Table 1.4 HIRA of HEMAT Factory

No. Activities Hazard

Potential Hazard Effect

Hazard

Level

Level of

Possibility Risk Prevention

Final

Risk

1 Material and

product shipping

and loading

-Material &

product spilled

and scattered

-Fall

accidentally

-Product got

damaged

-Environment got

dirty

-Workers got

injured

-Company incure

losses

M L M - Clear standard of procedure

-Usage of personal protective

equipment

- Well trained workers

L

2 Transporting/mo

ving the material

to unit operation

-Material

spilled and

scattered

-Fall

accidentally

- Environment got

polluted

-Workersgot

injured

- Production

process delayed

M M M - Clear standard of

procedure


-Storing some material as

backup

L

3 Operating the

unit operations

- Leakage of the

unit operation

- Workers low

performance

- Fire ignition

- Explosion

- Unoptimal

process

-Worker got

fainted and

injured

H M H - Well fire extinguisher

system near the working area

- Routine maintenance of the

unit operations

- Clear standard of procedure


- Prepare first-aid kit

M

11


Table 1.4 HIRA of HEMAT Factory (Contd 1)

Source: Reproduced from brainstorming

After we identify the hazard, we should determine the important spots on our plant such as evacuation way, assembly point that can

be seen below.

No. Activities Hazard

Potential Hazard Effect

Hazard

Level

Level of

Possibility Risk Prevention

Final

Risk

4 Control panel

maintenance

Electrocuted - Burnt wound &

scar

- Physical defect

- Dead

H M H The complete usage of safety

equipment such as safety

gloves and safety shoes

M

5 Cleaning the

plant

location/utilities

- Slipped

- Fall from

specific height

- Broken bones

- Light injury

- Dead

H H H - Warning sign in dangerous

area


- The complete usage of

safety equipment

M

6 Instrumentations

Maintenance

- Fall from

specific height

- Body part got

injured by the

unit operation

- Electrocuted

- Broken bones

- Body

dysfunction and

health problem

- Dead

H H H - Warning sign in dangerous

area


- The complete usage of

safety equipment


M

12


Figure 1.1 Plant layout

Source: Group discussion

13


1.2. Waste Treatment

At each process in producing a product, it must produce waste, whether in

liquid, solid, or gas. This section has become an inseparable part of the production

process. Waste are substances or waste material resulting from a production

process, both industrial and domestic (household), whose presence at a particular

moment is not desired because the environment can degrade the quality of the

environment and have no economic value. Therefore, the processing of the waste

itself should be something really important for the creation of the factory and the

surrounding environment that is free from the dangers of waste. Moreover, the

purpose of processing the waste so that the company can increase the economic

value of the waste.

In the processing of industrial waste, to be dealt with very carefully

because if sewage directly discharged without being processed before, will cause

environmental pollution. In the manufacture of the product "HeMat" Synthetic

Chicken Meat, there is waste generated from the process, namely vegetables and

TVP wash water. The waste must be dealt with appropriately so that when

discharged into the environment does not cause environmental pollution.

1.2.1. Mushroom and Garlic Waste

Synthetic Chicken Meat products made from several materials, among

others, oyster mushrooms and garlic. From these materials, there are components

that are not desirable to go into the manufacturing process. Unwanted components

is called waste and must be handled appropriately. Examples of unwanted

components is the root of the oyster mushroom and the root of the garlic.

Prior to the process, unwanted components collected in the container.

Then, the contents of the container is shipped to fertilizer company to be made

into compost or organic fertilizer. This is because the nutrient-rich vegetable

waste needed for crops. In addition to the fertilizer company, leftover vegetable

waste is sent to the company used as fodder for poultry feed.

1.2.2. Mushroom and Garlic Wash Water

In the manufacturing process when entering the grinding process, the

materials to be used should be washed beforehand to prevent unwanted

contamination. Wash water is waste that needs to be addressed prior to discharge

14


into the environment. Characteristics of waste water will vary greatly depending

on the type of vegetable processed and processing techniques are used, such as

when washing, peeling, etc., and on us in the form of plant material, we used the

washing process.

The first step in wastewater treatment is to purify the washing water which

will then be used for the processing of vegetables. The steps shown in the figure

below:

Figure 1.2 Wash Water Purification in vegetable processing

Source: www.westfalia.com

In the beginning, there is a full bath area for mushrooms and garlic freshly

harvested. Mushrooms and garlic is still contaminated with various foreign

substances, such as insects, worms, humus and unwanted impurities.The high

content of organic substances in the wash water means that extensive treatment is

essential because it cannot be discharged into the sewerage system or the

15


environment in this condition. Mechanical separation of the solids is a simple and

cost-effective method of cleaning the wash water. This will automatically reduce

the cost of fresh water, and can store and dispose of residues.

A rake is the first cleaning stage in which coarse solids such as mushroom

and garlic roots or dirt are separated The pre-cleaned wash water is then rid of dirt

and sand in a sand trap; the water is further purified in a bowl strainer machine

and discharged into a settling tank. The wash water that has been treated in this

way is now pumped into the decanter. Any fine substances still contained in the

wash water are now continuously separated and discharged with a high dry

substance content. The separated solids can be collected in big tank and will be

moved into garbage disposal and the water that has been clarified by the decanter

is discharged into a retainer tank and release into the sewer.

An alternative method of purification of waste water washing treatment is

made with good infiltration. Infiltration wells are shallow wells that puts water

from or into natural aquifers beyond the river, but which has a partial layer. They

can be used to drain the catchment area or groundwater recharge, especially where

lower aquifer recharge due to low rock or soil permeability.

There charge wells will make waste from washing waster of vegetable

washing process seep into the ground. The purpose of making infiltration wells

include to improve the quality and quantity of ground water, helping to overcome

the problem of short age of water, and conserve water resources in the long term.

Infiltration wells will be created with a length of 1m diameter-2.5m and a depth of

about 2.5m. The lifetimes of absorption wells itself is usually 6-10years.

1.2.3. Equipment Sanitation Water

In addition to the wash water, there are other important aspects of the process

in the industry namely sanitary equipment. This is because the equipment used

will have direct contact with foodstuffs to be processed.

16


1.3. Regulation

Peformance test to comply with safety aspect must based on regulation

from government. So the product will easily obtain a marketing authorization

from the government for distribution. We have searched the government

regulation for synthetic chicken meat but based on source that we have done for

search, there are no government regulations for synthetic chicken meat, so we

search the regulation for processed chicken meat like nugget. The following table

is BPOM regulation for limit of microbial contamination in processed chicken

meat from Lampiran Peraturan Kepala Badan Pengawas Obat dan Makanan

Republik Indonesia HK.00.06.1.52.4011 tanggal 28 Oktober 2009.

Table 1.5 BPOM regulation for limit of microbial

Type of food Type of microbial

contamination Maximum limit

processed meat and

processed chicken

meat

ALT (30C, 72 h)

APM Koliform

APM Escherichia coli

Salmonella sp

Staphylococcus aureus

Clostridium perfringens

1x105 colony/g

10/g

< 3/g

negatif/25 g

1x102 colony/g

1x102 colony/g

Source: Badan Peraturan Obat dan Makanan

The type of food above is processed meat and processed synthetic meat that can

we used as based for our synthetic chicken meat product. We get references for

definition, requirements, pilot, examination, labelling and packaging for chicken

nugget that will we use for our synthetic chicken meat. The following table is

regulation from Standard Nasional Indonesia for chicken nugget.

Table 1.6 SNI for chicken nugget

No Type of test Unit Requirement

1

Condition

1.1 Aroma

1.2 Taste

1.3 Texture

-

normal, same as lable

normal, same as lable

normal

17


Table 1.6 SNI for chicken nugget (Contd 1)

No Type of test Unit Requirement

2 Another Object % b/b tidak boleh ada

3 Water % b/b maximal. 60

4 Protein % b/b min. 12

5 Fat % b/b maximal. 20

6 Carbohydrate % b/b maximal. 25

7 Calcium mg/100g maximal. 30

8

Food additive

8.1 Preservative

8.2 Color

- sesuai dengan SNI 01-

0222-1995

9

Metal contamination

9.1 Lead

9.2 Copper

9.3 Zinc

9.4 Tin

9.5 Mercury

mg/kg

maximal 2.0

maximal 20.0

maximal 40.0

maximal 40.0

maximal 0.03

10 Arsen contamination mg/kg maximal 1.0

11

Mocrobial contamination

11.1 Total plate count

11.2 Coliform

11.3 E. Coli

11.4 Salmonella

11.5 Staphylococcus aureus

colony/g

APM/g

APM/g

/25g

colony/g

maximal 5x104

maximal 10

< 3

negatif

maximal 1x102

Source: Standar Nasional Indonesia

the type of test on the regulation has been elaborated on the process of SNI for

each type of test. Which has been elaborated based on SNI chicken nuggets, tests

conducted will refer to :

18


1. SNI 19-0428-1998, Hints sampling of solids

2. SNI 01-2391-1992, How to test food and beverage

3. SNI 01-2894-1992, How to test food preservatives and additives that are

prohibited for food

4. SNI 01-2896-1998, Test methods for metal contamination in food

5. SNI 01-4866-1998, Test methods for arsenic contamination in food

6. SNI 01-2897-1992, Test methods for microbial contamination

7. SNI 01-02221995, food additives

Detail SNI of each such test will in the appendix.

1.3.1. Performance Test

In the production of a product, it is important to know how the durability

of the products so that manufacturers know anything just things that can damage

or reduce the quality of the product. Safety of food products associated with the

expiration date of the product, microbial growth and contamination with

chemicals or metals need to pass the maximum limit for human health. To ensure

that our products are safe for consumption, we plan to conduct performance tests

on safety aspects, such as microbial and chemical contamination test, and test

expiration date.

1.3.1.1. Microbial Contamination Test Method

Operating condition and packaging a food production greatly influence the

spread of microorganisms (bacteria, yeasts and fungi) are present. If the operating

conditions in the production of food products meet the standards then it can

control pantogen bacteria (that cause disease) by reducing the number of spoilage

microorganisms (which cause food to go) so as to help make food safe and can

extend the shelf life of food. Methods of testing microbial contamination in

processed meat products set out in ISO 2897: 2008.

The usual method used in testing the bacterial contamination is the TPC,

MPN, and methods of enrichment. Methods Total Plate Count (TPC) is a

calculation method to determine the number of microbes contained in a product

that is grown on an agar medium in the incubation temperature and time specified.

Microbial count showed that whether or not the product is safe for consumption

19


which is adapted to the standards set by ISO. Most Probable Number method

(MPN) is an estimate of the number of microbes in a food, by gathering at a

dilution rate into three or five tubes containing liquid media design with three

replications. Results of this test is discoloration or gas formation can be observed

visually. Interpretation of the results refer to Table MPN of bacteria FDA

Analytical Manual. Enrichment method involves the isolation and identification of

microbes, and the interpretation of results (negative per gram / ml or negative per

25 grams or per 100 g / ml). The maximum limit for microbial contamination can

be seen in BPOM regulation for limit of microbial table.

1.3.1.2. Testing of metal contamination in the food with AAS

A product can be contaminated from raw materials that are less good or

from water that contains excess metal, so testing is very important metal. AAS is a

method of analysis for the determination of metal elements and metalloid based

absorption (absorbance) radiation by bebar atom of the element. A sample can be

measured when the metal content of metals in the sample have been released from

the organic material. Contamination testing methods of chemicals in products

regulated in ISO 7853: 2013.

Before measured using AAS, the sample should be prepared in advance

and should in destruction to release the metal from organic materials. Metal

deliverance usually done at high temperatures. Samples in charge until a certain

volume using demineralized water or dilute acid and subsequently measured using

AAS.

The test results are usually in the form of standard raw curve, the metal

content in the sample can be determined. Corrected sample assay using blanks.

Conclusion The test results in the form of recommendations eligible or ineligible

based on ISO. The following table maximum requirement presence of metal in a

food product

20


Tabel 1.7 Maximum limit of microbial contamination

Chemicals Maximum Limit (ppm or mg/kg)

Arsen (Ar) 0.5

Cadmium (Cd) 0.3

Mercury (Hg) 0.03

Tin (Sn) 40

Lead (Pb) 1

Source: Standar Nasional Indonesia

1.3.1.3. Method of determining the shelf life of food products

Each food products, either fresh or processed / processed has shelf life

(time / resistance or power savings and durability) each are different. Shelf life is

different with the expiration date, shelf life which is more related to the quality /

quality of food (food quality), while the expiration date related to food safety

(food safety). A food product if it has exceeded its shelf life "are safe" for

consumption, but "in quality" is not guaranteed (not eligible). Expiration of a

product can be in the approximate shelf life determination method is the method

of Accelerated Shelf-Life Testing (ASLT). ASLT is a method by storing food

products in the environment that causes rapid deterioration, either in temperature

or humidity conditions higher storage space. Data quality changes during storage

is converted in the form of a mathematical model, then shelf life is determined by

extrapolation equation under normal storage conditions. Acceleration method can

be done in a shorter time with good accuracy. ASLT method that is often used is

the Arrhenius model and a model of critical water content

ASLT method Arrhenius models ASLT method Arrhenius models used to

estimate the shelf life of perishable food products by consequence chemical

reactions, such as fat oxidation, Maillard reaction, denaturation of proteins, and so

on. In general, the chemical reaction rate will be faster at higher temperatures,

which means the faster the degradation products occur. Food product shelf life

may be determined by the Arrhenius models of which are commercially sterile

canned food, powdered milk / formula, the product chips / snacks, fruit juices,

21


instant noodles, frozen meat and other food products containing high fat (fat

oxidation potential ) or that contain reducing sugars and proteins (potentially the

browning reaction).

Because the chemical reaction in general is influenced by temperature, the

Arrhenius models simulate the accelerated destruction of the product under

conditions of high temperature storage at temperatures above normal storage. The

rate of chemical reactions that can lead to damage of food products generally

follow the order of the reaction rate of the order of 0 and 1. The type of food

damage that follows a zero order reaction model is the enzymatic degradation (eg

in fresh fruits and vegetables as well as some frozen food) and fat oxidation

reaction (eg increase rancidity in foods frozen foods). While the type of damage

foodstuffs included in the order of the reaction is rancidity (eg in dried

vegetables), the growth of microorganisms, off flavor production by microbes,

damage and loss of vitamins in food quality protein (Labuza, 1982).

Order reaction equation 0

(1)

Order reaction equation 1

(2)

Where:

A = Quality value remaining after time t

Ao = Initial quality score

t = Storage time (in days, months or years)

k = Zero or one order reaction rate constants

Chemical reaction rate constant (k), either zero or one order, can be affected

by temperature. Because in general the faster chemical reactions occur at high

temperatures, the chemical reaction rate constant (k) will be greater at higher

temperatures

Psikrofilik microorganisms have the ability to grow at temperatures in the

refrigerator, especially between 0C and 5C. So long storage at these

22


temperatures both before and after freezing may result in damage to the microbe.

So try the storage temperature 18oC or lower. In the world of food technology,

reezeburn namely a change of flavors, discoloration, loss of nutrients and changes

the texture of frozen food will quickly occur if food is stored at temperatures

above minus 9C. To obtain the best results from frozen food, storage temperature

should be kept constant and not be higher than minus 17C, and should be

followed by good packaging or packaging standards for frozen foods.

Table 1.8. High quality life in temperature varians

Type of Food

High Quality Life (months)

-18C -12C -5C

Processed chicken

meat 12 - 18 8 2 - 3

Source: Siregar, 2010

1.4. Hazard Communication

Once a chemical has been classified, the hazard(s) must be communicated

to target audiences. As in existing systems, labels and Safety Data Sheets are the

main tools for chemical hazard communication. They identify the hazardous

properties of chemicals that may pose a health, physical or environmental hazard

during normal handling or use. The goal of the GHS is to identify the intrinsic

hazards found in chemical substances and mixtures, and to convey information

about these hazards.

The international mandate for the GHS included the development of a

harmonized hazard communication system, including labelling, Safety Data

Sheets and easily understandable symbols, based on the classification criteria

developed for the GHS.

In our HEMAT Synthetic Chicken Meat products, there are some hazard

communication that can be seen in the pictures below:

1.4.1. Food Allergen Icons

International Food Allergen Icons are easily recognizable symbols for use

in the food manufacturing and food warehouse environments that can be

recognized and understood regardless of a person's native language. The allergen

23


icons are available for use in the food industry at plant and warehouse locations

to:

Identify tools used for cleaning specific allergens.

Identify the presence of specific allergens in ingredients (i.e. place a milk

icon sticker on a pallet of bagged ingredients which contains milk powder)

Link to training material in situations where language barriers exist in

plants and can be bridged through icons used as a visual indication of the

presence of allergens.

Identification of a plant area, to indicate the presence of a specific

allergen.

For food allergen icons in our product, there are some hazard

communication that can be seen in the pictures below:

(a) (b)

(c)

Figure 1.3 Food Allergy Warning; (a) Peanut, (b) Soy, and (c) Egg

Source: http://www.compliancesigns.com/kitchen-safety-signs.shtml

24


Figure 1.4 Food Allergy Warning of Gluten


1.4.2. Food Safety Icons

International Food Safety Icons are simple pictorial representations of

important food safety tasks that can be recognized and understood regardless of a

person's native language. Uses of the Icons include, but are not limited to:

Food safety training materials

Signs or reminders at food and beverage workstations

Food preparation and storage equipment

Recipe cards

Food packages

For food safety icons in our product, there are some hazard communication that

can be seen in the pictures below:

Figure 1.5. Safe Food Handling


25


The picture above describes the procedure in storing our products before further

processing for consumption. So, we must follow the rules in order to keep the

product safe for consumption.

Figure 1.6. Cooking Method

Source: http://www.foodprotection.org/resources/food-safety-icons/icons.php

The picture above explains that in the cooking process of our products, required

temperatures absolutely right to be safe for consumption.

Figure 1.7. Potentially Hazardous Materials


Figure 1.7 explains that our products require time or temperature control for the

safety of our products. So, in the process of taking our product into a food

product is needed to control the time or temperature can be consumed safely.

26


Figure 1.8. Products Packaging


The picture above describes the packaging of our products are LDPE (Low

Density Polyethylene), which type of plastic can be recycled back.


CHAPTER 2

CONCLUSION

To reduce the risk of the hazard in HEMAT factory we can use prevention

such as:

a. Preparing first aid-kit

b. Using well trained workers

c. Using clear standard of procedures

d. The complete usage of safety equipment

e. Routine maintenance of the unit operations

There are two sources of waste from our production process which are

derived from mushrooms, garlic and wash water. Therefore, it takes a

special treatment to process the waste into something that is not harmful,

both for the environment and living beings.

The maximum limit of the product may be contaminated with microbes by

SNI average of 1x102 colony / g.

The maximum limit of the product may be contaminated with chemical

substances Pb and Cd according to SNI by 1 and 0.3 mg / kg.

The lower the storage temperature, the product will be the longer product

durability.

In our HeMat Synthetic Chicken Meat products, there are some hazard

communication that classified into two parts, namely food allergen icons

and food safety icons. these icons already mentioned in Hazard

Communication above.


REFERENCES

Seider W.D., Seader J.D., Lewin D.R. Soemantri W., 2009, Product and Process

Design Principles. Synthesis, Analysis and Evaluation, Wiley and Sons Inc

Wesselingh J.A., Kiil, S. and Vigild M.E., 2007, Design and Development of

Biological, Chemical, Food and Pharmaceutical Products, John Wiley


APPENDICES

final assignment product design

Documents