HACCP PLAN FOR CHOCOLATE INDUISTRY

SAFEENA P A

ROHITHA P R

PRESENTED BY

HACCP-HAZARD ANALYSIS CRITICAL CONTROL POINT

• Food safety management system.• It identifies , evaluate and controls hazards

which are significant for food safety.

HACCP-BENEFITS• Maximize product safety.• Improved management responsibility.• Improved process control.• Improved inspection testing.• Moving the industry towards a quality

management system.

HACCP- 7 PRINCIPLES1) Conduct hazard analysis.2) Determine the critical control point.3) Establish critical limits.4) Establish monitoring system.5) Establish corrective action.6) Establish verification procedures.7) Establish documentation.

MILK CHOCOLATE

• Production starts with top quality cocoa beans are processed to produce the cocoa mass - which contains 53% cocoa and cocoa butter - the basis for all chocolate products.

• Sugar is added to the condensed milk with some of the cocoa mass, making a rich creamy chocolate liquid, which is then evaporated to make milk chocolate crumb.

CHOCOLATE MAKING

RECEIVING

SPLITTING

FERMENTATION

DRYING

ROASTING

WINNOWING

GRINDING

CONCHING

TEMPERING

MOULDING

PACKING

HAZARD ANALYSISPROCESSING STEPS

PHYSICAL HAZARD

CHEMICAL HAZARD

BIOLOGICAL HAZARD

1)RECEIVING Wood, chaff, plant materials

pesticides, fertilizers Worms ,insects

2)SPLITTING Metal pieces Chemicals from equipments

Contamination from handlers

3)FERMENTATION Wood pieces - Microbes(Salmonella spp )

4)DRYING Dust , foreign matters

- mold

5)ROASTING - - Microbial growth due to insufficient roasting

5)WINOWING Dust ,foreign matters in air

Polluted air contamination

Microbes (contaminated air)

7)GRINDING Metals Chemicals from equipments

Microbial contamination

PROCESSING STEPS

PHYSICAL HAZARDS

CHEMICAL HAZARDS

BIOLOGICAL HAZARDS

8)CONCHING Stone and other materials from raw materials

- Microbial contamination

9)TEMPERING Metal fragments Contamination from poorely maintained equipment

-

10)MOULDING Dust particles,plastic materials

- Uncleaned moulds

11)PACKING Foreign matter Labelling ink and packaging material

-

CONTROL MEASURE AND CRITICAL CONTROL POINT

PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL POINT/CONTROL POINT

RECEIVING P-sortingC-chemicals free materialsB-proper building setting

CP1

SPLITTING P-magnetic seperatorC-sanitize the equipmentB-personnel hygiene

-

FERMENTATION P-visual inspectionB-proper maintenance of fermentation tanks

CP2

DRYING P-visual inspectionB-proper maintenance of time and temperature

CP3

PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL POINT/CONTROL POINT

ROASTING B-Roasting of cocoa beans in stated period of time and temperature

CCP1

WINNOWING P,C,B-use of air filters CP4

GRINDING P-visual inspectionC-sanitize the equipmentB-sanitize the equipment

-

CONCHING P-Visual inspectionB-proper maintenance of equipment

CP5

TEMPERING P-visual inspectionC-Sanitize the equipment CP6

MOULDING P,B-Use of properly maintained moulds

CP7

PACKING P-Use of metal detectorsC-Use of appropriate packaging material and labelling ink

CCP2

CONTROL POINTS

• CP1- PRP No:9• CP2- PRP No:4• CP3- PRP No:4• CP4- PRP No:3• CP5- PRP No:7,14• CP6- PRP No:4,7• CP7- PRP No:1

CRITICAL LIMITS

• CCP1 - Roasted in special ovens at temperatures between 105-120ºC. The actual roasting time depends on whether the end use is for cocoa or chocolate

• CCP2 - Wrapping of chocolate done at aseptic condition.

MONITORING 1)RECEIVING CHECK :Visual inspection of incoming goodsRECORD : presence or absence of contamination2) SPLITTINGCHECK: Regular inspection of equipmentRECORD: Record any resulting maintenanceCHECK : Supervisory check of personnel hygieneRECORD : Record any incident of poor personnel hygiene on

personnel record3)FERMENTATIONCHECK : proper checking of fermentation tanksRECORD : presence or absence of contamination

MONITORING4)DRYINGCHECK :Drying temperature and time RECORD : temperature and time is noted.5)ROASTINGCHECK : Proper temperature and time for roastingRECORD : Temperature and time is noted6)WINNOWINGCHECK : Personnel hygiene and sanitation of equipmentRECORD : Record any incident of poor personnel hygiene on

personnel record7)GRINDINGCHECK : Visual inspectionRECORD : record any resulted maintenence

MONITORING8)CONCHINGCHECK : Regular inspection of equipment RECORD : record any resulted maintenance9)TEMPERINGCHECK : Regular inspection of equipmentRECORD : record any resulted maintenance10)MOULDINGCHECK: Proper maintenance of moulds11)PACKINGCHECK : Visual controlRECORD : Packaging checks.

CORRECTIVE ACTIONS1)RECEIVING Reject contaminated cocoa pods2)SPLITTING Maintain personnel hygiene and equipment sanitization3)FERMENTATIONProvide good condition to avoid microbial attack4)DRYINGDry the product to stated period5)ROASTINGRoasted to stated time and temperature6)WINNOWINGProvide good quality of air

CORRECTIVE ACTIONS7)GRINDINGProper maintenance of equipment8)CONCHINGRaw material maintenance9)TEMPERINGProper Cooling and heating 10)MOULDINGProduct will be retained and reworked or discarded11)PACKINGMaintain aseptic condition and proper cleaning of

packaging plant

•Staff training purpose•Suppliers in the case of any disputes or problems•Customers confidence•Food safety inspection•Frequency of cleaning equipment•Critical control point records•Personnel hygiene records•Raw materials records•Record any resulting maintenance record•Inspection of equipments record•Time-temperature record

DOCUMENTATION