haccp in food industry

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HACCP in spice in


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HACCP plan IN SPICE INDUSTRY Presented by: Sariga S KCAET, Tavanur


HACCP HACCP stands for ‘Hazard Analysis Critical Control Point’. HACCP is a system which looks for and prevents potential problems before they happen. HACCP may be used by food companies to make sure they do not break the law by putting consumers at risk when producing food .

The HACCP Approach :

The HACCP Approach HACCP is based on identifying significant biological, chemical, or physical hazards at specific points within a product’s flow through an operation Once identified, hazards can be prevented, eliminated, or reduced to safe levels

For HACCP to be Effective:

For HACCP to be Effective It must be specific to each operation’s menu, customers, equipment, processes, and operations A plan that works for one operation may not work for another

What does it involve?:

What does it involve? Identifying points during the production of a product where potential hazards may occur . Analysing the risk of the hazard points happening including the scale of consequence if they do Deciding which points are critical to consumer safety . Implementing controls, monitoring production and taking action if necessary . Reviewing the HACCP plan whenever the food operation is altered, and on a regular basis, e.g. annually, even if no alterations have been made.

Qualities of the HACCP system:

Qualities of the HACCP system HACCP is: Systematic Efficient On the spot.


Hazard The types of hazards which a HACCP plan can focus on include Biological hazards, e.g. Harmful microorganisms Chemical hazards, e.g. Those either naturally occurring intentionally added or unintentionally added Physical hazards, e.g. Glass, stones or metal Packaging quality Equipment reliability


PHYSICAL HAZARDS Physical hazards usually result in personal injuries, such as a cut from glass or a case of choking from foreign materials . Stones , dirt, wire, string, stems, sticks, nontoxic foreign seeds, excreta, manure and other animal contamination Physical hazard points of entry into the products are in the field, in-transit, deliberate by employees or others, equipment failure, and poorly maintained facilities and equipment

PowerPoint Presentation:

1. Aspirator (Air separator) 2 . Rotary knife cutter 3. Destoner 4 . Vacuum gravity separator (Air table) 5. Clinder separator (Indent) 6 . Sifter Aspirator 7. Plain sifter 8 . Spiral gravity separator 9. Air screen separator


CHEMICAL HAZARDS C hemicals in processing facilities and manufacturing plants that should be rigorously controlled . Sanitizers, lubricants, pest control chemicals used within a processing facility Water treatment additives, chemicals added to the manufacturing process for a specific process.

chemical hazards found in spices:

chemical hazards found in spices Naturally occurring Mycotoxins such as aflatoxin Added Chemicals Agricultural products, pesticides, fertilizers, antibiotics, other field chemicals Toxic elements, lead, mercury, and other heavy metals Food additives, such as preservatives, flavor enhancers, color additives Allergens


BIOLOGICAL HAZARDS Temperature and humidity The bacterial and fungal species in spices include aerobic spoilage organisms, spore forming bacteria , high heat stable toxin producing bacteria, proteolytic and gas-producing bacteria, and mycotoxin -producing microorganisms. Of all the spices, black pepper typically has the highest aerobic plate counts, usually in excess of 10 6 cfu / g . Paprika, celery seed, coriander, turmeric, thyme , basil and other spices can also have plate counts in the millions per gram.

Common microorganisms found in spices:

Common microorganisms found in spices Bacteria Salmonella, C. perfringens , Bacillus cereus, E. coli, Staphylococcus aureus Fungi, Yeast and Molds Aspergillus , Penicillium ssp. Mycotoxins Examples of mycotoxins include but are not limited to: Aflatoxin , Ochratoxin and Vomitoxin . Low levels of mycotoxins , when found, are most commonly present in capsicums , turmeric, ginger, nutmeg, mace and white & black pepper.

Sources of microbial contamination are: :

Sources of microbial contamination are: Growing, drying, and harvesting Poor import/export procedures Processing Improper storage and distribution temperatures and handling Poor personal hygiene among food handlers and production workers.

Critical Control Point (CCP):

Critical Control Point (CCP) A Critical Control Point (CCP) is an identifiable point in the production chain where a hazard may occur. This can either be a point, step or procedure at which control can be applied and is essential to prevent or eliminate a hazard or reduce it to an acceptable level.

Critical Control Point (CCP):

Critical Control Point (CCP) Chemical residue can be prevented by control at the receiving stage Chemical hazard can be prevented by control at the formulation or ingredient-addition stage Pathogenic bacteria growth can be controlled by refrigerated storage or chilling Pathogenic bacteria can be killed during cooking Metal fragments can be detected by a metal detector and eliminated by removing the contaminated product from the processing line Parasites can be killed by freezing

Critical Control Point (CCP):

Critical Control Point (CCP) Pathogenic bacteria can be killed during cooking; Metal fragments can be detected by a metal detector and eliminated by removing the contaminated product from the processing line; Parasites can be killed by freezing . The occurrence of foreign objects can be minimised by manual sorting and automatic collectors; Some biological and chemical hazards can be minimised by obtaining shellfish from approved waters.

The Seven HACCP Principles:

The Seven HACCP Principles Conduct a hazard analysis Determine critical control points (CCPs) Establish critical limits Establish monitoring procedures Identify corrective actions Verify that the system works Establish procedures for record keeping and documentation

Processing of Garlic :

Processing of Garlic

PowerPoint Presentation:

Raw material (Garlic) Washing (water spraying/Rotary washers) Peeling (steaming, Radiant treat / Flames) Washing (spraying water) Dehydration (modern Dehydrators Pulverisation (Hammer mill) Coarse powder ( Bo mesh sieve) Screening Process Step Garlic Powder Dehydrated Garlic powder Packing (PE bags)

1. Conduct a hazard analysis :

1. Conduct a hazard analysis The first step involves identifying any hazards that must be prevented, eliminated or reduced to acceptable levels. All potential hazards, from the receipt of raw materials through to release of the finished product, must be considered. A hazard must be controlled if it is likely to occur, and/or likely to result in an unacceptable risk to consumers.

Assessing Food Hazards :

Assessing Food Hazards

Assessing Food Hazards :

Assessing Food Hazards

2. Determine critical control points (CCPs) :

2. Determine critical control points (CCPs) Identifying the Critical Control Point (CCP) at the steps or at which control is essential to prevent or eliminate a hazard or to reduce it to acceptable levels.

3. Establish critical limit :

3. Establish critical limit A critical limit is a maximum or minimum value to which a biological, chemical or physical limit must be controlled at a CCP. This is set in order to prevent, eliminate or reduce a hazard to an acceptable level.

PowerPoint Presentation:

Raw material (BPC) Washing (BPC) Peeling (steaming, Radiant treat / Flames (BC)) Washing (spraying water(BPC )) Dehydration ( BPC) Pulverization (Hammer mill) (P) Coarse powder ( BPC) Screening Dehydrated Garlic powder (BPC ) Packing (PE bags ) BPC)

PowerPoint Presentation:

Raw material (BPC) Washing (BPC) Peeling (steaming, Radiant treat / Flames (BC)) Washing (spraying water(BPC )) Dehydration ( BPC) Pulverization (Hammer mill) (P) Coarse powder ( BPC) Screening(p) Dehydrated Garlic powder (BPC ) Packing (PE bags ) BPC)

4.Establish monitoring procedures:

4.Establish monitoring procedures A planned series of observations or measurements need to be taken to assess whether a CCP is within critical limits. This also helps to produce an accurate record for future use in verification

PowerPoint Presentation:

RAW MATERIALS Check : Visual inspection of incoming materials Record: Presence/absence of contamination on invoice WASHING Check - Regular inspection of articles/ equip,water Record - Record any resulting maintenance Check - Supervisory check of personal hygiene Record - Record incidents of poor personal hygiene on personnel record

PowerPoint Presentation:

PEELING Check - Visually check the garlic for the period stated in the suppliers instructions Record - not applicable PULVERISATION Check - Visually check powdered to a desired mesh size Record -Not applicable SCREENING Check - size of powder Record - Size of powder

PowerPoint Presentation:

DEHYDRATION Check : using thermometer Record : temperature and time PACKING Check : visual control Record : packaging checks

5. Identify corrective actions :

Corrective actions, are procedures to be followed when a hazard is identified in the food production (deviated from Critical limit) . The aim is to correct and eliminate the cause of the hazard and bring CCP back under control. The cause of problem must be identified to prevent future recurrence . Establishing corrective actions when monitoring procedures at CCP is not under control. 5. Identify corrective actio ns

PowerPoint Presentation:

Listed below are some questions that might help when developing corrective actions: How will people be informed when the deviation occurs? Who will be responsible for controlling the product that may have been affected by the deviation? How will we decide what caused the deviation? Who will be involved in deciding how to get the process back in control? Who in the company needs to sign off on any modifications to plan? Who will be responsible for keeping the records of things done in response to a deviation from a critical limit?

PowerPoint Presentation:

Raw material Reject contaminated or out of date code foods , Avoid entry to the process lines Preparation: washing Repair/replace defective articles/equip. Retrain food handlers Peeling Reject unpeel garlic

PowerPoint Presentation:

Pulverisation Reject unpulverised powder Screening - Repair/replace defective screen Dehydration dry up to safe moisture content ture per batch Packing Washout the material from packaging plant

6. Verification :

Verification procedures are those activities, other than monitoring CCPs, that verify the HACCP plan and show the system is operating according to the plan. This is usually completed annually or when a system fails or there is a significant change in the product or process. Establishing procedures, which shall be carried out regularly to verify that the measure outlines in the above paragraphs. 6. Verification

PowerPoint Presentation:

There are three types of verification: Validation , the initial phase in which the plan is tested and reviewed. Ongoing verification , that ensures that the HACCP plan is working effectively on a day-to-day basis. Typically verification includes management review and sign off. Reassessment , an overall review of the plan that must be performed at least annually , or whenever any changes occur that could affect the hazard analysis or alter the HACCP plan.

7. Documentation :

7. Documentation Documentation and record keeping help to demonstrate the effective implementation of the previous principles of HACCP . This records could be of the development of the HACCP plan, CCP monitoring, corrective actions or verification activities . • Staff training purposes • Suppliers in the case of any disputes or problems • Customer confidence • Food safety inspection visits or investigations

Types of documentation :

Types of documentation • Hazard analysis plans • Staff training records • Food temperature records • Time records • Cleaning schedules and records • Working procedures • Audit records • Equipment records (including calibration checks)

PowerPoint Presentation:

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