towards haccp · yeast •main danger: yeast and moulds from the air. yeast and moulds are present...
TRANSCRIPT
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Towards HACCPHazard Analysis + Critical Control Points
Preventing a problem rather than solving it when it has happened
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Why HACCP
• Assure safety of consumers
• Financial: Reduce wastage
• Image: Meet consumer demands
• Meet regulations
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Doing things right
• Always strictly controlling all the steps• Higher quality
• Less problems
• Less spoilage
• Less consumer complaint
• GAP: Good Agricultural Practices
• GMP: Good manufacturing Practices
• GHP: Good hygiene practices
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Basic hygienic production• Clean water
• Clean equipment and utensils• Metal mixing spoon
• Use of liquid soap
• Hand washing
• Clean clothing
• Shelter for kitchen
• Packaging room: smooth surfaces
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The most critical steps in yoghurt making
• The milk should not have antibiotics
• The yoghurt should not have contaminations (cow hairs, ash, dust, others…)
• Heating should be long and hot enough
• Every time after cooking you expose the milk/yoghurt, the shelf life decreases.
• Store yoghurt at 2 - 5 °C, max 10 °C during transport
• Keep preferably for 24 hours in the fridge before transport and sales: thickness increases
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Yeast
• Main danger: Yeast and moulds from the air. Yeast and moulds are present in high numbers on surfaces. On the skin of one person, 1 000 000 000 000 bacteria are present!!!
• Cause gas production (bulging of packages)
• Use cleanable equipment, utensils and surfaces.• Boiling water
• JIK (bleach)
• Avoid ventilation
• Avoid any contact with the air as much as possible!!!
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Controlling the process
• If you test the end product, it is already to0 late… Control the process!
• Mistake that is a danger to health and safety of the customer: Critical Control Point (CCP)
• Mistake that makes poor quality yoghurt: Control Point (CP)
• Set targets for the CCP’s and the CP’s to see if they are under control
• Set corrective actions
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Hazards
• Different types of hazards:• Biological: bacteria, yeast
• Physical: cow hairs, ash, dust
• Chemical: detergents, antibiotics
• Danger to safety and quality
• Assure absence at point of consumption
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Hazards come from…
• In raw material (milk, sugar, packaging material)
• During process• Environment
• Equipment
• Personnel
• Hazards that survive (not enough heating)
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Hazard analysis
• The likelihood and consequence of micro-organisms present.
• Floor plan with potential routes of cross contamination
• Vulnerability of consumers
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Floor plan
Milk reception
Packed yoghurtMilk
Pasteurization
Ferm
enta
tio
n
Pack
ing
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Yoghurt production process
1. Raw milk (cooler or can)
2. Pasteurization
3. Cooling and adding starter
4. Fermentation
5. Packing, storage, distribution
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HACCP plan yoghurt productionStep Type Prevent Target Check Correct
1 Raw milk Microbial Train farmers on hygiene
CP Observe farm practices
Reject
1 Raw milk Antibiotics Inquire from farmer
CCP Absent Observe farm practices
Reject
1 Raw milk Impurities Filter CCP Absent Visual Filter
2 Pasteurization,milk and sugar
Microbial Temperature and time
CCP 85 °C, 15 min Watch, thermometer
Re-do
2 Pasteurization Microbial Cleaning GMP Hold in boiling water
Wash
2 Adding sugar Impurities Dissolve and filter
GMP No visual impurities
Visual Re-do
3 Cooling Microbial Temperature CCP 45 °C Thermometer Cool more or heat up
3, 4, 5
Cooling and fermentation and packaging
Microbial Keepcovered, use clean equipment
CCP Covered, put equipment in boiling water
Visual Cover, clean/boil
5 Storage,distribution
Microbial Temperature CP 4 °C Thermometer Adjust fridge
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Verification• Lab test
• Consumer complaints
• Work instructions well communicated: Everybody follows the correct production procedure and hygiene measurements
• Records of milk quality and spoilage rates.
• Review the procedure in case of new type of product/new production site/new equipment/packaging
• In case of poor quality/failure/consumer complaints• What is the cause?
• How to prevent it from happening again?
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Simple improvements to the production process
To minimize contaminations
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Sources of contamination
• Raw materials
• Dirty or old milk will bring out low quality yoghurt
• Utensils/ Equipment (tables, cardboards, covers/lids, pans, cans,
buckets, stirring stick, etc.)
• Environment (design of the unit, storage conditions, water,
temperature and air)
• Be careful with the water used for cleaning!
• Personnel skin and clothing
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Sources of contamination
• Additives (sugar, flavors, stabilizer, fruits)
• Sugar needs to be boiled together with the milk!!
• Keep the lid of flavors and other additives (stabilizer etc) closed!
• Packaging materials and packaging method
• Sometimes its needed to clean bottles
• Don’t enter with your hands into the buvera
• Soil and drains
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Simple improvements in the production process• Strictly use metal utensils
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Essential equipment
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Prepare yoghurt from tightly closed cans, and not on direct fire
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Prepare from smooth surfaces
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Walls
• Smooth
• Bright colored
• Cleanable
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Smooth ceiling to prevent dust and contamination
• Ceiling should be high enough
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Floors
• Made of material (cement, concrete, terrazzo or tiled) that is easy to wash and dry
• Drainage systems should be kept clean
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General guidelines
• Enough light, either natural or electricity • Don’t expose sockets to water• Proper ventilation • No windows near dirty places• Enough dustbins• Dustbins in appropriate places• Enough water for washing hands and
utensils• Toilets available• Change into clean clothes and clean
shoes when entering (changing room)
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Wear appropriate clothing and cover hair
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Personal Hygiene
• All staff members should be medically examined every six months• Diseases that are transferable in food
• Do not work if you suffer from flu, vomiting, diahoerrea or any related disease
• Hand washing: all the time, after toilet use, using soap
• Protective clothing: clean clothes, only used inside
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Make a plan
What When Who Costs
Buy plunger August Chairman 200.000
Attend DDA training school Entebbe