HACCP PLAN FOR FRUIT JUICE INDUTRY

Presented by, Ajna

Alavudeen

HACCP

HACCP is a management system in which food safety is addressed through the analysis and control of biological , chemical , physical hazards from raw materials production and handling to manufacture , distribution and consumption of the finished products.

SEVEN PRINCIPLES??? List all food hazards that are reasonably likely to

occur. List the caps. List the critical limit that that shall be met at each

caps. List the monitoring procedures. Include any corrective action plans. List the validation and verification procedures. Provide for a record keeping system.

JIVE Kerala horticultural development program

fruit processing factory. Products: R.T.S, Candy, Concentrated mango

pulp line .

READY TO SERVE

This is a type of fruit juice which contain at least 10% fruit juice.

10% TSS. About 0.3% acid. Not diluted before serving.

PROCESSINGFruit

Mixing with strained syrup solution(sugar +water +acid)

Heated

Homogenization

Sterilization

Filling tetra packing

Cooling

storage

HAZARDS IN PROCESSING

Processing stage

Physical contamination

Chemical contamination

Biological contamination

Receiving of fruit

Sand , pest, stones, wood

Naturally occurring substancesPesticides, fungicidesToxic chemicals,mycotoxin.

Presence of microorganism

StorageSand ,stones, wood

Chemical contamination

Presence of microorganism

Cleaning Poorly maintained equipments

Chemical Contaminations in water

Microbial quality of waterCross contaminationQuality of water,Cross contamination.

Belt washing d Chemical contamination in water,Excess sanitation

Microbial cross contamination, microbial quality of water

Peeling Presence of metal pieces

Chemical contaminations from chemical or pesticides

Contamination due to unclean equipment

Pulping Presence of metal pieces, foreign body or dust contamination from production environment.

none Contamination due to un clean equipment.

Mixing Screw, metal pieces

none Cross contamination

Holdingh Contaminations from warehouses practices

None Cross contamination

Strainer None None Cross contamination

Thermal processing

Unsanitized equipment.

Sanitizer residue

Microbial survival due to insufficient temperature or holding time.

Cooling None Sanitizer residue None

Tetra Packaging None Microbial contamination due to CIP.

MEASURES CONTROL MEASURES AND CRITICAL CONTROL

Process step Physical hazards

Chemical hazards

Biological hazards

CP/CCP

Receiving of fruit

Visual interpretation ,Weighing unfit fruit is rejected

Random sampling,Guarantied supplier

Visual inspection,Sorting prior to processing

CP

Storage Visual interpretation

none Maintain ideal storage condition

CP

Cleaning Regularly check the equipments.

Use 200ppm chlorine water

Regular testing for microbial quality of water

CP

belt conveyor washing

NoneRegular testing for chemical quality of water

Regular testing for microbiological quality of water

CP

Peeling Precaution for maintenance ,screens, magnet downstream will remove debris

None Precaution for cleaning ,sanitizing equipment

CP

Pulping Precaution for maintenance ,screens, magnetDownstream will remove debris

none Precaution for cleaning, sanitizing equipment

CP

Mixing Use of metal detectors

CP

Holding tank Personnel hygiene policies were adopted

Regular testing for chemical quality of water

G CP

Strainer Precaution for cleaning and sanitizing equipments

Thermal processing Temperature &pressure should be maintained

CCP

Cooling section Temperature should be maintained& is equipped with temperature sensors.

CP

Tetra packaging Visual inspection

Correct Cleaning procedures have to be follow

CP

CRITICAL LIMITS

Sterilization: temperature;121ºc for 15 psi.

MONITORING

Receiving of fruitsCheck : visual inspectionRecord: Presence/absence of contaminants in goods Storage of fruits Check : regular inspectionRecord :any security maintenance PeelingCheck : regular inspectionRecord: record any security maintenance PulpingCheck: regular inspectionRecord: record any security maintenance

MixingCheck the equipments regularlyRecord any security maintenance HoldingCheck: StrainerCheck : regular inspection of equipmentsRecord : Record any resulting maintenance Thermal processingCheck: Using thermometers and temperature sensorsRecord : Temperature and time Tetra packCheck : visual checkRecord :filling check

CORRECTIVE ACTIONS

Purchase/delivery –reject contaminated or unripe fruit

Storage- repair/replace storage structure

Cleaning – contaminated water is eliminated

Belt washing- contaminated water is eliminated

Peeling – repair defective articles

Holding tube – precaution during sampling

Strainer – replace defective article

Thermal processing- boil up to the stated period

Cooling process- cool up to the stated period

Filling –discard defect product during filling

DOCUMENTATION Audit records Equipment records Product records Staff records Cleaning schedule records Customer confidence records Hazard analysis plan Record the inspection visit or investigation

THANK YOU