haccp plan soy-based sauce production (sosrojakbuah

HACCP PLAN Soy-Based Sauce Production (Sos Rojak Buah)

Sem. 2, 2017/2018

NAME MATRIC NO

Farah Adleen Zakaria 189451

Suganthi D/O Selvadurai 189563

Nurelyzurina Sukri 190103

Nor Farzana Mohd Razali 190265

Muhammad Muhsin Mohamed Makki 190510

INTRODUCTION

This case study included:

The preliminary of HACCP – list out the product description & the process flow diagram

The disadvantages of the current production & the improvement

Based on the improvement :-

identify hazard analysis + critical control points (CCPs) Specify the critical limits Described approciate monitoring activites for each CCPs Design the corrective ction for each CCPs & how will it will

be reviewed in the future.

OBJECTIVES

• Execute all the seven main principles of the Codex Alimentations approach to

HACCP.

• Determine the appropriate level detail that is needed in HACCP plan.

• Understand how using HACCP helps to achieve Quality Assurance.

• Appreciate other benefits of HACCP system.

HACCP TEAM

Muhammad Muhsin Mohammed Makki

Production operator

Nor Farzana MohdRazali

Food technology

Farah Adleen Zakaria

Quality assurance

Suganthi A/P Selvadurai

Hygiene manager

Nurelyzurina Sukri

Maintenance

PRODUCT DESCRIPTION

1. Product name Sos Rojak Buah

2. Type of product Ready-to-eat

3. Shelf-life of the product under proper

storage conditions

9 months at room

temperature

4. Raw materials shrimps paste, sweet soy

sauce, sugar, salt, sesame

and chili powder.

CURRENT FLOW CHART

CURRENT PRODUCTION PROCESSES AND IMPROVEMENT

• Did not have a proper place for storage and process as they made the sauce inside their house

• Food packaging did not have expired date and nutritional table for the reference for the consumer

• The finished product was stored at ambient temperature

• Use full manual system will results in low productivity

Disadvantage of

Current Process

IMPROVED FLOW CHART

Improvement suggestion based on pre-requisite program (PRP) knowledge

1. Training

- To create awareness among employees on GMP.

2. Standard Operation Procedure (SOP)

- Ensure consistency in daily operations. Simple, detailed, written.

3. Industry Design – Ventilation

- Protect air quality/odor/temperature/humidity.

4. Good Hygiene Practice (GHP)

- Provide a clean sanitary environment for every process.

5. Personal Hygiene

- Health status and personal cleanliness

HAZARD EVALUATION

Process

Step

Potential Hazards Likelihood Severity Risk

factor

Is this a signification

hazard?

What measures can be applied

to control this significant hazard

Cooking B Clostridium perfringens

Clostridium botulinum

Salmonella

3 6 18 Yes Ensure adequate cooking

C Sanitizer residue 2 4 8 Yes Minimize usage of sanitizer

P Foreign materials 2 4 8 Yes Install detection and

elimination system

Hot filling B Clostridium perfringens


Salmonella

3 6 18 Yes Maintain the temperature of

hot filling

C None identified


elimination system

Process

Step

Potential Hazards Likelihood Severity Risk factor Is this a

signification

hazard?

What measures can

be applied to

control this

significant hazard

Capping B Clostridium

perfringens

Clostridium

botulinum

Salmonella

3 6 18 Yes Capping quickly to

prevent pathogens

growth

C None identified


elimination system

CRITICAL CONTROL POINTS (CCP)

Process step in the food processing where a food hazard can be prevented, eliminated or reduced to an

acceptable level

CODEX

DECISION TREE

Process

Step

Potential Hazards Q1: Are there

control

measure(s) for the

significant

hazard?

Q2: Is the process

step specifically

designed to

eliminate or

reduce the likely

occurrence of the

significant hazard

to an acceptable

level?

Q3: Could

contamination

occur at

unacceptable

level or increase

to

unacceptable

level ?

Q4: Will a

subsequent

process step

eliminate or

reduce the

significant

hazard to an

acceptable level?

Is this

Critical

Control Point

(CCP)

Cooking B • Clostridium

perfringens

• Clostridium

botulinum

• Salmonella

Yes

Adequate cooking

eliminate the

pathogens

presence

Yes

Cooking can kill

Clostridium and

salmonella

CCP-1

C Sanitizer residue Yes

use of sanitizer according to manufacturer’s instruction

No

cooking is not to eliminate sanitizer residue

Yes

High sanitizer residue can lead to health problem to consumer

No

Other process

cannot eliminate

this hazard to

acceptable level

CCP-1

P Foreign materials Yes

Install detection and elimination system

No

Cooking is not a process to eliminate foreign materials

Yes Food contamination may occur

No

Other process

cannot eliminate

this hazard to

acceptable level

CCP-1

Process

Step


control

measure(s) for the

significant

hazard?

Q2: Is the

process step

specifically

designed to

eliminate or

reduce the likely

occurrence of

the significant

hazard to an

acceptable level?

Q3: Could

contamination

occur at

unacceptable level

or increase to

unacceptable level

Q4: Will a

subsequent

process step

eliminate or

reduce the

significant

hazard to an

acceptable level?

Is this

Critical

Control Point

(CCP)

Hot filling B Clostridium

perfringens

Clostridium

botulinum

Salmonella

Yes

Maintain the

temperature of

hot filling

eliminate the

pathogens

presence

Yes

Hot filling can kill

Clostridium and

salmonella

CCP-2

C None identified



No

Hot filling is not a process to eliminate foreign materials


No

Other process

cannot eliminate

this hazard to

acceptable level

CCP-2

Process

Step


control

measure(s) for

the significant

hazard?

Q2: Is the process

step specifically

designed to

eliminate or

reduce the likely

occurrence of the

significant

hazard to an

acceptable level?

Q3: Could

contamination

occur at

unacceptable

level or increase

to

unacceptable

level

Q4: Will a

subsequent

process step

eliminate or

reduce the

significant

hazard to an

acceptable level?

Is this

Critical

Control

Point

(CCP)

Capping B Clostridium

perfringens

Clostridium

botulinum

Salmonella

Yes

Maintain the

temperature of

product to

eliminate the

pathogens

presence

Yes

Capping can kill

clostridium and

salmonella

CCP-3

C None identified



No

Capping is not a process to eliminate foreign materials


No

Other process

cannot eliminate

this hazard to

acceptable level

CCP-3

CRITICAL LIMITS

Maximum or minimum value to which a biological, chemical or physical parameter must be controlled at a

CCP to prevent, eliminate or reduce to an acceptable level for the occurrence of a food safety hazard

Process Step Potential Hazard Critical Limits

CCP-1

Cooking (B)

Clostridium perfringens


Salmonella

Ensure cooking temperature

above 73oC

CCP-2

Hot filling (B)



Salmonella

Maintain hot filling

temperature above 60oC

CCP-3

Capping (B)



Salmonella

Ensure the cap is fit with the

plastic bottle and check the

integrity of the cap to prevent

any damage

MONITORING ACTIVITIESMonitor is 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

CORRECTIVE ACTION

Procedures followed when the monitoring result show that a critical points derivates from the critical limits.

CCP and

Process

Monitoring procedures Corrective action

CCP-1

Cooking

• Measure the product’s internal

temperature. These temperature

readings must be taken each time a

batch of sauce is cooked.

• Calibrate the thermometer to ensure it

is working correctly before measuring

the product’s internal temperature.

• Record the results on the “Sauce

Cooking Record,” including the date, the

time, and initials.

• Causes of the deviation will be identified

and eliminated

• Measures all the associated paramaters

to prevent recurrence of the hazards

CCP and

Process


CCP-2

Hot filling

• Operator’s must ensure the

temperature of cooked sauce above

60oC to prevent contamination and

growth of pathogen occur.

• Install thermometer alarms that display

the current temperature. If the

temperature reached room

temperature that operator fixed, the

alarm will trigger.

• Recook the product

• Separate and hold the product for a

safety evaluation.

• Adjust the cooking equipment to

increase the processing temperature

CCP and

Process


CCP-3

Capping

• The environment of bottling and

capping need to ensure clean and dry to

prevent cross contamination.

• Workers hygiene ensured before

packaging process starts.

• Swab table tops, packaging surfaces,

workers gloves, aprons, etc., that make

contact with exposed cooked product.

• Manager/ supervisor must always

check whether workers follow the SOP.

• Divert the product to a use in which the

critical limit is not applicable (e.g.,

divert to others operation).

• Identify and correct the source of the

defect.

CONCLUSION

• The improvement that have been proposed are to increase the quality of the product (ex: shelf life :12months) and its potential to be widen in the market.

• Some steps are proposed such as preparing the raw materials, hot filling, capping, labelling and chill storage to improve the product so that it will be consumed by more people and also to eliminate several potential hazards along the production process.

• Moreover, to make sure the product is been qualified to be widen in the market. Thus, the valid licensed food businesses is needed by proposing this HACCP.

THANK YOU

haccp plan soy-based sauce production (sosrojakbuah

Documents