Studies on the Quality Assurance (QA) System in Selected Sea Fish Processing Units in Khulna, Bangladesh

Presented byMd. Shabudden Ahmed (FN 06047)Sifat Mohammad Arefin (FN 06031)

Md. Akhterujjaman (FN 06017)

Supervised by

A.K. Obidul HuqAssistant Professor

Department of Food Technology and Nutritional ScienceMawlana Bhashani Science and Technology University, Tangail.

Introduction

Shrimp is the second largest foreign exchange earner for Bangladesh which earned as much as US$ 437.40 million in the year 2009-10.

The European Commission (EC) imposed a ban on shrimp from Bangladesh into the EU in 1997 on the ground that export of shrimp did not meet the provisions of her (HACCP).

Hazard Analysis Critical Control Point (HACCP) and GMP are internationally recognized as the best method of assuring product safety by controlling food borne safety hazards.

A strong monitoring system comprises with technical personnel and corrective action should be installed in each industry to maintain the quality and assure the food safety through HACCP, GMP and ISO standard.

Introduction continue

Objectives of the Study

To observe the plant layout and infrastructure of selected Sea fish industries at Khulna.

To justify the personal hygiene practice of worker and employee of the industries.

To find out the interrelated factor for determining the food safety and quality factor and evaluate the quality assurance system in technological application of the industries.

Materials and MethodsStudy AreaThis study is based on four selected seafood industries are Atlas Seafood Ltd., Lockpur Fish Processing Co. Ltd, Organic Shrimp Export Ltd. and New Food Ltd. The factories are located at shore of Rupsha river, Rupsha, Khulna, Bangladesh.

Fig. 1. Map showing the study area (Source: Banglapedia, 2008).

Materials and Methods (Continued)

Study DesignThis study is design by descriptive and observational cross sectional study.

Study Period:Study period of the research project work was November 2011 to April, 2012.

Results and Discussions

Indutry Name

Establishing Year

Types of Factory

Measurement of factory premises

No. of products

Brand Name

ASFL 2003 Private 1 acre 15-16 Atlas

LFPCL 1987 Private 2.5 acre 10 Sea star &

Bonoful

OSEL 2004 Private 1.5 acre 8 White Gold

NFL 1994 Private 2.2 acre 11 Red Rose

Table-1: Background information of selected industry*

** ASFL = Atlas Sea Food Ltd, LFPCL = Lockpur Fish Processing Co. Ltd, OSEL = Organic Shrimp Export Ltd, NFL = New Food Ltd.

Figure: Potential hazards as identified at different steps

Receiving

Prior to processing

Washing

Personal Hygiene

Factory Hygiene

Freezing & Chilling

Cooking & Glazing

Packaging

Storage

ShipmentCultivation

Farm to Factory

Export

Figure : Preferable Certificate Required by Importers

HACCP Certificate45%

ISO Certificate22%

BRC Certificate33%

Acceptancy of Required Certificate for Export

Figure: Achievement of Certificate in Abroad.

ASFL LFPCL OSEL NFL

BRCISOHACCP

Name of the Industry

No.

of C

ertifi

cate

Figure : Distribution of the industry according to hygiene practices abide by workers

ASFL LFPCL OSEL NFL70.00%

71.00%

72.00%

73.00%

74.00%

75.00%

76.00%

77.00%

78.00%

Name of the Industries

Cond

ition

of H

ygie

ne P

racti

ce

Figure : Effective method of Personnel hygiene Training.

UNIDO50%

FIQC20%

Own Factory22%

Other8%

Effectiveness of Personal Hygeine Training

Figure: Schedule of training program of personal hygiene.

UNIDO ( 3 months interval) FIQC (6 month interval) FACTORY OWN (0.5 month interval)0

2

4

6

8

10

12

14

Interval of Training ProgramM

onth

Figure: Processing Type of Product

0%20%40%60%80%

100%

AutomatedManual

Name of the Product

Prod

uctio

n Pr

oced

ure

Figure: Wastage ratio of the Selected Industries

Product (rest of waste)36%

P&D34%

Washing12%

Cooking18%

Amount of Waste in Different Steps

Figure : Capacity of the finished product storage

ASFL LFPCL OSEL NFL0

10000

20000

30000

40000

50000

60000

70000

Name of the Industries

Capa

sity

of S

tora

geeg

e

Table: IPC(In Process Control), CCP system for production, Lab analysis.

IPC (In

process

Control)

[f (%)]

CCPs for

production

[f (%)]

Critical

record

system

[f (%)]

Chemical

analysis

[f (%)]

Microbiolog

ical analysis

[f (%)]

Yes 4(100) 4(100) 4(100) 4(100) 4(100)

No 0 0 0 0 0

Total 4(100) 4(100) 4(100) 4(100) 4(100)

Table: Interval of Inspection of Microbial and Chemical Hazard of Product

Name of the Analysis Test Interval

Microbial Analysis Standard Plate Count Every Batch

Coliform & Fecal Coliform

Salmonella

V. Cholerae

Shigella

Chemical Analysis Antibiotic test Every Collection

of Raw Materials

Filth Test Whole insect Every Batch

Insect Fragment

Hair

Organoleptic Test 1. Temperature (<5ºC), Smell Before Receiving

Table: Water and Ice Analysis of the IndustriesSample

Collection

Point

Microbiological

Parameters

Max.

Acceptable

Limit

Physio-

Chemical

Parameters

Max. Acceptable

Limit

Over Head

Tank,

Receiving

Line, Chill

Water Tank,

Glazing,

Pressure Wash

Line, Flake Ice

Room, Ice

Basket, Block

Ice

S.P.C/ml at 37ºC

for 48 Hours

10/ ml Temperature

Total Coliform/

100 ml

Nil PH 6.5-8

E. coli/ F.

Coliform/ 100 ml

Nil Iron Nil

Vibrio Cholerae Absent Chlorine < 5 ppm

Salmonella Absent Colour Natural

Table: Hygiene practice (monitoring committee, permission of disease worker)

Monitoring of Hygiene

Practices

YES NO

Number of

Industry

% Number of

Industry

%

HACCP Team 4 100% 0 0

Safety & sanitation

monitoring committee

4 100% 0 0

Monitoring system

about personnel hygiene

practices

4 100% 0 0

Allow the diseased

personnel to work

3 75% 1 25%

Table: Schedule of HACCP Training Program

Training topic Duration Participant

Personal Hygiene and

Cleanliness

4 weeks (3 hours duration) Supplier, Production/ cold

storage supervisors,

worker & Sweeper

Sanitation 4 weeks (3 hours duration) Do

Sensory Evaluation 4 weeks (3 hours duration) Supplier, Receiving-in-

charge & supervisor,

Production-in-charge

Frozen/ Cold storage

Management

4 weeks (3 hours duration) Cold storage-in-charge,

supervisor, workers

Maintenance of

Equipments

2 months Machine Foreman,

operator and helpers

Recommendations

The male workers are less sincere on the personal hygiene practice so a strong monitoring system and corrective action are required.

None of the industries has nurse or health worker to take care if any worker become sick accidently, so the authority of the industries should take step.

Due to excessive load shedding the quality of product are damage badly. So the government should take initiative step to assure the incessant supply of electricity with special consideration.

Conclusions

Among the daily worker the male workers are less sincere to practice personal hygiene than female workers. Cooked IQF shrimps are comparatively safe and qualified for export purpose as the maximum processing steps are done automatically. The Importers like to see the “Seal of Quality” which certified by the third party of the international organization. This normally requires a cooperative effort between a country’s industry and government and its external partners.

Different Finished Product in the Sea Fish Industries

Processing Units of Sea Fish Industries in Khulna, BD

Thanks for Listening