Haccp of pineapple canned in syrup

ByMs.Atcharaporn Khoomtong st113172 FEBT

HACCP for Fruit ProcessingCase study: Canned Pineapple sliced

in syrup

12 Steps of HACCPAssemble HACCP Team Describe Product Identify the intended use Construct flow diagram On-site confirmation of flow diagramConduct a hazard analysis. Identify critical control points. Establish critical limits for each critical control point.Establish critical control point monitoring requirements.Establish corrective actions. Establish record keeping procedures. Establish procedures for verifying the HACCP system is

working as intended.

2

7 Principle

HACCP Team Leader

HACCP Team

Assemble HACCP team

3

Establish HACCP TeamName Position/

DepartmentExperience

Mr. ABM Production Manager(HACCP Team

leader)

B.Sc Food TechnologyGMP,HACCP

Miss FEBT Quality Assurance Manager

B.Sc Food ScienceGMP,HACCP

Mrs.SET Assistant Manager of Research

Development

B.Sc Food ScienceGMP,HACCP

Mr.SERD Engineering Supervisor

B.Sc Food TechnologyGMP,HACCP

Mrs.SET Purchasing Manager Bachelor degree MarketingGMP,HACCP

4

Product Description and Intended UseProduct name Canned pineapple in syrup

Important product characteristic of product(aw, pH, etc.)

Sliced pineapple ,added syrup Brix 14-18 ,Commercial sterilize, pH not more than 4.2,No pathogenic Bacteria, The color of the product shall be normal for the varietal type

How is it to be used Ready to eat

Packaging The product is packed in tin can* size A2(20 oz) , end coated with lacquer place in corrugated carton, sealed with PP tape and strapped with plastic strapped.

Shelf life 3 years from production date in original pack at mentioned storage condition.

Storage Store in dry condition at room temperature 25- 30 ๐C

5Note * mean"Tin" cans are made of tinplate (tin-coated steel). In some locations, cans made of aluminum are called "tin cans".

Product Description and Intended Use

Where will it be sold foreign market

Labeling instructions name or trademark identifying a product , manufacturer, lot, manufacture date, expiry date, ingredient, Drained Weight in grams, Net Weight

Target group of customers Food industry and General consumer.

Intended use Food industry and General consumer.

Distribution Control Keep the product in dry place during distribution, storage and handling. Con’

6

Plant Layout

7

Raw Material and Ingredient

8

Raw material/

Ingredients

appearance

storage package

size

Pineapple Fresh, whole

Room temp.Not more than 2 days

- -

Sugar Crystals,white

Dry@Room temp.2 years

PE bag 50 Kgs

Citric acid Crystals,white

Dry@Room temp.2 years

PE bag 50 Kgs

Hazard occurence in process step / Environment of Production

Biological Chemical PhysicalPathogenic Bacteria: Bacillus cereus: Salmonella Spp.: E.coli: Coliform bacteria: Staphylococcus aureus: Clostridium botulinum: Clostridium Perfringens: Flat Sour group: Aciduric spoilage group

Yeast & Mold

From Raw material- Herbicide- Heavy metal- Nitrate-From Equipment-Lubricant-From Tin cans-Tin-Lacquer-Rusty- From Sanitizing Chemical :Detergent :Chlorine : Sodium hydroxide : Nitric acid

- Wood - Metal - Plastic - Sand - Jewelry- Glass

9

Flow diagram

2 Sorting

3 Washing [Residual Cl2 20-40 ppm]

4 Grading

5 Peeling

6 Trimming

7 Slicing

8 Filling into cans10

9 Receiving Tin Cans

10 Washing

11 Water

11 Water

Cl2

CCP1

Con’

12 Added syrup (Packing Media)

13 Exhausting

14 Seaming

15 Cooking

16 Cooling [Residaul Cl2 not less

than 0.2 ppm]

17Storage

18 Labeling 11

Flow diagram19

Receiving Citric acid

20 Unloading

21 Receiving

Sugar

22 Unloading

23 Mixing&he

ating

24 Filtering

25 Syrup Storage(Media)

26Soft

Water

Verified byMr.TPlant

Manager15/09/11

CCP2

CCP3

CCP4

CCP5

CCP6,

CCP7

Decision tree

12

HACCP Analysis

13

Con’

Process step

Hazards and possible causes

Control measures Q1

Q2

Q3

Q4 Y/N

1 Receiving Pineapple

BIO. Salmonella spp., E. coli, Clostridium Perfringens Staphylococcus aureus, Exist: from rotten fruit, Fertilizer (plantation)

Pathogenic bacteria &Yeast &Mold Contamination: From trucks

Approve supplier list ;Raw Material Specification & Record

Truck inspection & Record

Y N Y Y N

CHEM.Herbicide Contamination: From plantation

Approve supplier list (GAP), Fertilizer & Chemical Control& Analysis of external lab

Y N N - N

HACCP Analysis

14

Con’

Process step

Hazards and possib

le causes

Control

measures

Q1 Q2 Q3 Q4

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

1 Receiving Pineapple

CHEM. CON’NitrateContamination: From plantation

Oil & LubricantContamination: From trucks

Fertilizer & Chemical ControlRecord Nitrate Inspection

Raw Material Specification, Record Oil & Lubricant Contamination

Y

Y

N

N

Y

N

Y

-

N

N

PHYS.Wood, SandContamination: From Supplier

Raw Material Specification, Record Foreign Matter

Y N N - N

HACCP Analysis

15Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

2 Sorting

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment

Cleaning Program & Record

Y N Y Y N

CHEM.LubricantContamination: From machine

Sanitizing chemicalContamination: From cleaning

Preventive Maintenance, Check Lubricant Contamination

Cleaning Program & Record, Chemical Residual

Y N N - N

PHYS.No perceived hazard

- - - - - -

HACCP Analysis 16Con’

Process step


Control measures Q1

Q2

Q3 Q4 Y/

N

3 Washin

g (Residual Cl2 20-40

ppm.)

BIO. E. coli, Coliform bacteriaContamination: From Water

Pathogenic bacteria GROWTH:From dirty water collect

Water Treatment Control & Record

Change water (over flow or drain every hour)

Y

Y

N

N

Y

Y

Y

Y

N

N

CHEM.High chlorine Contamination: From Water treatment

Sanitizing chemicalContamination: From cleaning


Cleaning Program &Record,Chemical Residual

Y

Y

N

N

N

N

-

-

N

N


- - - - - -

HACCP Analysis

17Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

4 Gradin

g

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment (Grader)

Cleaning Program & Record,Sanitation Inspection Record

Y N Y Y N



Y N N - N


- - - - - -

HACCP Analysis

18Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

5 Peeling

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment (GINAGA)

Cleaning Program & Sanitation Inspection RecordSwab Test Program & Record

Y N Y Y N



Y N N - N

PHYS.Metal fragments Contamination: : From Equipment (GINAGA)

Preventive Maintenance, Record

Y N Y Y N

19

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

6 Trimming

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment (TRIMMER)

E. coli, Coliform bacteria,Staphylococcus aureusContamination: From Workers


Personal Hygiene & Record,Swab Test Program & Record

Y

Y

N

N

Y

Y

Y

Y

N

N

CHEM.Sanitizing chemicalContamination: From cleaning


Y N N - N

HACCP Analysis

HACCP Analysis

20

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

6 TrimmingCON’

PHYS.Metal fragments Contamination from machine (TRIMMER)

JewelryContamination: From Workers

GlassContamination: From Light bulbs

Preventive Maintenance,

Personal Hygiene & Record,

Glass control

Y

Y

Y

N

N

N

Y

N

N

Y

-

-

N

N

N

Con’

21

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

7 Slicing(SLICER)

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment (SLICER)




Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N

HACCP Analysis

22

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

7 Slicing(SLICER)CON’



Y N N - N

PHYS.Metal fragments Contamination from machine (Knife)

JewelryContamination: From Workers

Preventive Maintenance,


Y

Y

N

N

Y

N

Y

-

N

N

HACCP Analysis

Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

8 Filling into cans

BIO. Pathogenic bacteria &Yeast &Mold Contamination: From Equipment (BELT CONVEYER / FILLER)




Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N23

HACCP Analysis

HACCP Analysis

24

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

8 Filling into cansCON’

PHYS.JewelryContamination: From Workers

GlassContamination: From Light bulbs


Glass control

Y

Y

N

N

N

N

-

-

N

N

Con’

HACCP Analysis

25

Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

9 Receiving Tin Cans

BIO. Bacillus spp. & MOLD EXIST

Bacillus spp. & MOLD, E. coli, Coliform Staphylococcus aureus RecontaminationFrom Double seam defect (supplier)

Approve supplier list ; Empty Can Inspection & Record

Empty Can Inspection (Tear down & Visual Seam)

Y

Y

N

Y

Y

-

Y

-

N

CCP1

CHEM.Oil & LubricantContamination: From machine

Approve supplier list , Oil & Lubricant Contaminate Inspection

Y N N - N

HACCP Analysis

26

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

9 Receiving Tin CansCON’

PHYS.Metal fragments Contamination: From TIN Plate

Foreign Matter Contamination Inspection

Y N N - N

Con’

HACCP Analysis

27

Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

10 Washing

BIO. PestContamination: Can storage

E. coli, Coliform ContaminationFrom Water

Pest Control & Record


Y

Y

N

N

Y

Y

Y

Y

N

N

CHEM.Rusty canContaminationHigh Chlorine Concentration


Y N N - N


- - - - - -

HACCP Analysis

28

Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

11 Water

BIO. E. coli, Coliform ContaminationFrom Water


Y N Y Y N

CHEM.High Chlorine Concentration:From Over f eeded Cl2 water


Y N N - N


- - - - - -

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

12 Added Syrup(Packing media)

BIO. Clostridium botulinum GROWTHFrom : High pH

Pathogenic bacteriaYeast &Mold Contamination: From Equipment

Packing Media Control (pH) & Record


Y

Y

Y

N

-

Y

-

Y

CCP2

N



Y N N - N

PHYS.GlassContamination: From Light bulbs

Glass control Y N N - N

HACCP Analysis

29

HACCP Analysis

30Con’

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

13Exhausti

ng

BIO. Bacillus cereus, Bacillus coagurans SURVIVAL Flat sour group, Aciduric Spoilage groupFrom Low initial temperature

Initial Temperature Control & Record

Y Y - - CCP3



Y N N - N


- - - - - -

Process step

Hazards and possible causes Control measures Q

1Q2

Q3

Q4 Y/N

14Seamin

g

BIO. E. coli, Coliform bacteria, Staphylococcus aureusRecontaminationFrom Double seam defect

Tare down & down visual seam inspection & record

Y Y - - CCP4


Oil & LubricantContamination: From machine( SEAMER )

Cleaning Program & Record


Y

Y

N

N

N

N

-

-

N

N


- - - - - -

HACCP Analysis

31

Con’

HACCP Analysis

32Con’

Process step


1Q2

Q3

Q4 Y/N

15Cooking

BIO. Bacillus cereus, Bacillus coagurans Flat sour group, Aciduric Spoilage group SURVIVALFrom Inadequate temperature & Time cooking

Cooking water temp.& cooking time

Y Y - - CCP5

CHEM.No perceived hazard

- - - - - -


- - - - - -

HACCP AnalysisProcess step


1Q2

Q3

Q4 Y/N

16Cooling

BIO. E. coli, Coliform bacteria, RecontaminationFrom Cooling water

Bacillus cereus, Bacillus coagurans Flat sour group, Aciduric Spoilage group SURVIVAL From High CCT. After cooling

Residual chlorine control in cooling water (Not less than 0.2 ppm) & record

Center Can Temperature After Cooling control & Record

Y

Y

N

N

Y

Y

N

N

CCP6

CCP7

CHEM.No perceived hazard

- - - - - -


- - - - - -

33Con’

HACCP Analysis

34Con’

Process step


1Q2

Q3

Q4 Y/N

17Storage

BIO. No perceived hazard

- - - - - -

CHEM.High TIN content not more than 200 ppm

Tin Content Specification & Record Check before loadingShelf life not more than 3 years.

Y N N - N


- - - - - -

HACCP Analysis

35

Process step


1Q2

Q3

Q4 Y/N

18Labeling

BIO. Pathogenic bacteria Growth:From shelf life product more than shelf show in label

Label inspection& record and labeling & casing inspection

Y N N - N

CHEM.High TIN content not more than 200 ppm

labeling & casing inspection

Y N N - N


- - - - - -

HACCP Analysis

36

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

19 Receiving Citric acid


- - - - - -

CHEM.Impurity (Heavy metal) Contamination

Approve supplier list , Analysis heavy metal from supplier, COA (Certificate of authentic)

Y N N - N


Citric Acid Inspection (Foreign Matter)& Record

Y N N - N

37

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

20 Unloading





Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N

HACCP Analysis

HACCP Analysis

38

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

20 UnloadingCON’


PlasticContamination: From Citric acid bags


Preventive Maintenance, Strainer

Y

Y

N

N

N

N

-

-

N

N

Con’

HACCP Analysis

39

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

21 Receiving Sugar


- - - - - -

CHEM.Impurity (Heavy metal) Contamination

Approve supplier list , Analysis heavy metal from supplier, COA(Certificate of authentic)

Y N N - N


Citric Acid Inspection (Foreign Matter)& Record

Y N N - N

40

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

22 Unloading





Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N

HACCP Analysis

HACCP Analysis

41

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

22 UnloadingCON’


PlasticContamination: From Sugar bags


Preventive Maintenance, Strainer

Y

Y

N

N

N

N

-

-

N

N

Con’

42

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

23 Mixing&Heating

BIO. Clostridium botulinum GROWTHContamination: From HIGH pH

Pathogenic bacteria &Yeast &Mold Contamination: From Equipment

Packing Media Control (pH) & Record


Y

Y

N

N

Y

Y

Y

Y

N

N


Cleaning Program, Check Chemical Residual

Y N N - N

HACCP Analysis

HACCP Analysis

43

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

23 Mixing&HeatingCON’

PHYS.PlasticContamination: From Sugar and Citric acid bags

Preventive Strainer & Check Strainer

Y N N - N

Con’

HACCP Analysis

44

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

24 Filtering

BIO. Pathogenic bacteriaYeast &Mold Contamination: From Equipment


Y N Y Y N



Y N N - N

PHYS.Metal fragments Contamination: From strainer

Preventive Strainer & Check Strainer

Y N N - N

45

Process step


Control measures Q1

Q2

Q3

Q4 Y/N

25 Syrup storage


Pathogenic bacteria &Yeast &Mold Contamination: From Delay time


Delay time control (not more than 8 hrs)

Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N


- - - - - -

HACCP Analysis

HACCP Plan

Process step

Hazard Critical limit

Control measur

es

Monitoring method

Corrective/PreventiveAction

Receiving Tin Cans

BIO: Bacillus spp. & MOLD, E. coli, Coliform Staphylococcus aureus RecontaminationFrom Double seam defect (supplier)

Not foundCritical&majorDefect seam(Visual seam)

Empty can(Visual seam inspection)

WHAT: Critical&majorDefect seam

HOW :Visual external seam inspection

WHEN: every lot

WHERE:Incoming area

WHO:QA . Inspector

DURING PROCESSLINE: RejectWHO: QA . Supervisor

FINISHED PRODUCTPRODUCT: Hold (Sorting 100%)

WHO: QA . Supervisor

46

CCP1: Step 9 Receiving Tin Cans

Con’

HACCP Plan

Process step


Control measur

es

Monitoring method

Corrective/PreventiveAction

Added Syrup(Packing media)

BIO: Clostridium botulinum growthFrom: High pH

pH not more than 4.2

pH Meter (Check pH Eqilibrium product)

WHAT: pH

HOW :Check pH Eqilibrium product

WHEN: First time,every code,every hour

WHERE:Packing media inspection area

WHO:QA . Inspector

DURING PROCESSLINE: Adjust pHWHO: operator

FINISHED PRODUCTPRODUCT: Hold (Incubation 14 Days)


47

CCP 2: Step 12 Added Syrup (Packing media)

Con’

HACCP Plan

Process step


Control measure

s

Monitoring method

Corrective/Preventive

Action

Exhausting

BIO: Bacillus cereus, Bacillus coagurans SURVIVAL Flat sour group, Aciduric Spoilage groupFrom Low initial temperature

Can size<A10 not less than 60 ˚C

Note(A2 =20 oz.)

Check initial temperature before seaming

WHAT: initial temperature

HOW :Check initial temperature before seaming

WHEN: First time,every code,every 30 Mins

WHERE:Packing media inspection area

WHO:QA . Inspector

FIRSTOPERATIONLINE: until reach temp required and recheckWHO: production line

DURING PROCESSLINE: stop process until reach temp required and stop cooking time

FINISHED PRODUCTPRODUCT: Hold (Incubation 14 Days)WHO: QA . Supervisor

48

CCP3: Step 13 Exhausting

Con’

HACCP Plan

Process step


Control measur

es

Monitoring method


Action

Seaming BIO. E. coli, Coliform bacteria, Staphylococcus aureusRecontaminationFrom Double seam defect

Not foundCritical&majorDefect seam(Visual seam)

Empty can(Visual seam inspection)

WHAT: Critical&majorDefect seam

HOW :Visual external seam inspection

WHEN: Every 30 minsOperating seamer for visual checkWHERE:Seamer area

WHO:QA . Inspector

DURING PROCESSLINE: stor&seamer adjustWHO:Operator/Mechanic

FINISHED PRODUCTPRODUCT: Hold (Sorting 100%)


49

CCP4: Step 14 Seaming

Con’

HACCP PlanProcess

stepHazard Critical

limitControl

measures

Monitoring method


Action

Cooking BIO: Bacillus cereus, Bacillus coagurans Flat sour group, Aciduric Spoilage group SURVIVALFrom Inadequate temperature & Time cooking

Temp not less than 97˚CA2 >20 min

Temperature recorder(Check temperatureCommercial Sterilization)

Check time control

WHAT: Cooking water temperature (MIG)and Cooking time

HOW :Check temperatureCommercial Sterilization

WHEN:every 30 Mins (T)(productn line) /every 1 hour(T)(QA line)

WHERE:Cooking area

WHO:QA . Inspector&productn line

DURING PROCESSLINE: stop process until reach temp required and stop cooking timeWHO: operator/QA . Supervisor



50

CCP5: Step 15 Cooking

Con’

HACCP Plan

Process step


Control measur

es

Monitoring method


Action

Cooling BIO. E. coli, Coliform bacteria, RecontaminationFrom Cooling water

Residual Chlorine not less than 0.2 ppm

Chlorine test kit(LOVIBON)

WHAT: Residual Chlorine in cooling water

HOW :Check Residual Chlorine

WHEN: every 2 hours by cooker

WHERE:Cooker area


DURING PROCESSLINE: Adjust Residual Chlorine until required (minimum 0.2ppm)WHO: operator



51

CCP6: Step 16 Cooling

Con’

HACCP Plan

Process step


Control measur

es

Monitoring method


Action

Cooling BIO: Bacillus cereus, Bacillus coagurans Flat sour group, Aciduric Spoilage group SURVIVAL From High CCT. After cooling

CCT not more than45˚C

Center can temperature inspection after cooling (CCT)

WHAT: CCT after cooling

HOW :Check CCT after cooling

WHEN: every 4 hours by cooker

WHERE:Cooker area


DURING PROCESSLINE: Increasing flow rate of cooling waterWHO: operator



52Con’

CCP7: Step 16 Cooling

Verification Plan

53

Calibrate seam micrometer Every 6 months

Calibrate pH Meter Everyday before operation

Calibrate Thermometer Every 3 months

Calibrate Timer Every month

Refresh Training operator @ CCP point

Every year

External lab for inspection finish product

Every year

Internal audit GMP/HACCP Every 6 months

External lab for inspection WATER

Every year

Verified HACCP Documents (From step 1 – step 12)

Every year or Anytime that production line/Ingredient was changed)

54

Thank you for your attention ka/krub

Haccp of pineapple canned in syrup

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