haccp of pineapple canned in syrup

By

Dr.Atcharaporn Khoomtong

HACCP for Fruit ProcessingCase study: Canned Pineapple sliced in syrup

12 Steps of HACCP

Assemble HACCPTeam Describe Product Identify the intended use Construct flow diagram

On-site confirmation of flow diagram

Conduct 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

HACCP Team Leader

HACCP Team

Assemble HACCP team

3

Establish HACCP Team

Name Position/Department Experience

Mr. Been Production Manager(HACCP Team leader)

B.Sc Food TechnologyGMP,HACCP

Miss Happiness Quality Assurance Manager B.Sc Food ScienceGMP,HACCP

Mrs.Glady Assistant Manager of Research Development

B.Sc Food ScienceGMP,HACCP

Mr.Canny Engineering Supervisor B.Sc Food TechnologyGMP,HACCP

Mrs.Pineapple 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, DrainedWeight 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

10

CCP1

Con’ 11

Flow diagramCCP2

CCP3

CCP4

CCP5

CCP6, CCP7

Dec

isio

ntr

ee

12

HACCP Analysis

13Con’

Processstep

Hazards and possible causes

Control measures Q1 Q2 Q3 Q4 Y/N

1 Receiving Pineapple

BIO. Salmonella spp., E. coli, Clostridium PerfringensStaphylococcus 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.HerbicideContamination: From plantation

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

Y N N - N

HACCP Analysis

14Con’

Processstep

Hazards and

possible causes

Control measures

Q1 Q2 Q3 Q4

Processstep



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’

Processstep



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

stepHazards and

possible causesControl measures Q1 Q2 Q3 Q4

Y/N

3 Washing (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’

Processstep



4 Grading 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’

Processstep



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

Processstep



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

Cleaning Program & Record, Chemical Residual

Y N N - N

HACCP Analysis

HACCP Analysis

20

Processstep



6 TrimmingCON’

PHYS.Metal fragments Contamination frommachine (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

Processstep



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

Processstep



7 Slicing(SLICER)CON’



Y N N - N

PHYS.Metal fragments Contamination frommachine (Knife)

JewelryContamination: From Workers

Preventive Maintenance,


Y

Y

N

N

Y

N

Y

-

N

N

HACCP Analysis

Con’

Processstep



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 - N

23

HACCP Analysis

HACCP Analysis

24

Processstep



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

25Con’

Processstep



9 Receiving Tin Cans

BIO. Bacillus spp. & MOLD EXIST

Bacillus spp. & MOLD, E. coli, ColiformStaphylococcus aureusRecontaminationFrom 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

Processstep



9 Receiving Tin CansCON’

PHYS.Metal fragments Contamination: From TIN Plate

Foreign Matter Contamination Inspection

Y N N - N

Con’

HACCP Analysis

27Con’

Processstep



10 Washing BIO. PestContamination: Can storage

E. coli, ColiformContaminationFrom 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

28Con’

Processstep



11 Water BIO. E. coli, ColiformContaminationFrom Water

Water Treatment Control & Record Y N Y Y N

CHEM.High Chlorine Concentration:From Over f eededCl2 water


Y N N - N


- - - - -

Processstep



12 AddedSyrup(Packing media)

BIO. Clostridium botulinumGROWTHFrom : 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’

Processstep



13Exhausting

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

Initial Temperature Control & Record

Y Y - - CCP3


Cleaning Program & Record,Chemical Residual

Y N N - N


- - - - -

Processstep



14Seaming

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

31Con’

HACCP Analysis

32Con’

Processstep



15Cooking

BIO. Bacillus cereus, Bacilluscoagurans 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

stepHazards and

possible causesControl measures Q1 Q2 Q3 Q4 Y/N

16Cooling

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

Bacillus cereus, Bacilluscoagurans 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’

Processstep



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

Processstep



18Labeling

BIO. Pathogenic bacteriaGrowth: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

Processstep



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 stepHazards and


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




Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N

HACCP Analysis

HACCP Analysis

38



20 UnloadingCON’


PlasticContamination: From Citric acid bags


Preventive Maintenance, Strainer

Y

Y

N

N

N

N

-

-

N

N

Con’

HACCP Analysis

39

Processstep



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



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




Y

Y

N

N

Y

Y

Y

Y

N

N



Y N N - N

HACCP Analysis

HACCP Analysis

41



22 UnloadingCON’


PlasticContamination: From Sugar bags


Preventive Maintenance, Strainer

Y

Y

N

N

N

N

-

-

N

N

Con’

42



23Mixing&Heating

BIO. Clostridium botulinumGROWTHContamination: 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



23 Mixing&HeatingCON’

PHYS.PlasticContamination: From Sugar and Citric acid bags

Preventive Strainer & Check Strainer

Y N N - N

Con’

HACCP Analysis

44

Processstep



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



25 Syrup storage

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

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

PHYS.No perceived hazard - - - - - -

HACCP Analysis

HACCP Plan

Process step Hazard Critical limit Control measures

Monitoring method

Corrective/PreventiveAction

Receiving Tin Cans

BIO:Bacillus spp. & MOLD, E. coli, ColiformStaphylococcus aureusRecontaminationFrom 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


Monitoring method

Corrective/PreventiveAction

AddedSyrup(Packing media)

BIO: Clostridium botulinumgrowthFrom: High pH

pH not more than 4.2

pH Meter (Check pH Eqilibriumproduct)

WHAT: pH

HOW :Check pH Eqilibriumproduct

WHEN: First time,everycode,every hour

WHERE:Packing mediainspection 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 PlanProcess step Hazard Critical limit Control

measuresMonitoring

methodCorrective/Preventive

Action

Exhausting BIO: Bacillus cereus, BacilluscoaguransSURVIVAL Flat sour group, AciduricSpoilage 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 :Checkinitial temperature before seaming

WHEN: First time,everycode,every 30 Mins

WHERE:Packing mediainspection 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


Monitoring method

Corrective/Preventive

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 minsOperatingseamer 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 step Hazard Critical limit Control

measuresMonitoring

methodCorrective/Preventive

Action

Cooking BIO:Bacillus cereus, Bacillus coaguransFlat sour group, AciduricSpoilage 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)andCooking 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


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


Monitoring method


Action

Cooling BIO: Bacillus cereus, Bacilluscoagurans Flat sour group, AciduricSpoilage group SURVIVAL From High CCT.After cooling

CCT not more than45˚C

Center can temperature inspection after cooling (CCT)

WHAT: CCTafter 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

RefreshTraining 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