HACCP Plan for Industrial Manufacturing of Chocolate
•Descargar como PPTX, PDF•
10 recomendaciones•14,615 vistas
Haccp plan for industrial manufacturing of chocolate.This is complete HACCP plan for the chocolate manufacturing industry.
Recomendados
Recomendados
Más contenido relacionado
La actualidad más candente
La actualidad más candente (20)
Similar a HACCP Plan for Industrial Manufacturing of Chocolate
Similar a HACCP Plan for Industrial Manufacturing of Chocolate (20)
Último
Último (20)
HACCP Plan for Industrial Manufacturing of Chocolate
- 1. HACCP PLAN FOR INDUSTRIAL MANUFACTURING OF CHOCOLATE Abdul Rahman Tahir 1ABDUL RRAHMAN TAHIR
- 4. OVERVIEW Introduction HACCP Benefits Elements HACCP Plan Identification page Assemble the HACCP Team Intended Use Flow Chart HACCP- 7 PRINCIPLES HAZARD ANALYSIS CONTROL MEASURE AND CRITICAL CONTROL POINT CCP DECISION TREE CRITICAL LIMITS MONITORING CORRECTIVE ACTIONS DOCUMENTATION 4ABDUL RRAHMAN TAHIR
- 5. INTRODUCTION HACCP is abbreviation of Hazard Analysis and Critical Control Points Identifies, evaluates and controls hazards which are significant for food safety 5ABDUL RRAHMAN TAHIR
- 6. HACCP-BENEFITS Maximize product safety Improved management responsibility Improved process control Improved inspection testing. Moving the industry towards a quality management system 6ABDUL RRAHMAN TAHIR
- 7. ELEMENTS • A trained HACCP team • Product description • Intended use • Process flow diagrams • Hazard analysis, determine and establish Critical Control Points and corrective actions (HACCP Principle 1-4) • CCP Monitoring (HACCP Principle 5) • Verification process (HACCP Principle 6) • Record keeping (HACCP Principle 7) The elements suggested are as follows: 7ABDUL RRAHMAN TAHIR
- 8. HACCP PLAN IDENTIFICATION PAGE Product Chocolate Company name MAAN Lovebury Company Contacts 03000445516 Abdulrahmantahir786@gmail.com 8ABDUL RRAHMAN TAHIR
- 9. ASSEMBLE THE HACCP TEAM NAME POSITION Asad Ullah Tahir HR Manager Abdul Rahman Tahir Inspect receiving Muhammad Waseem Processing Muhammad Usman Maintenance Muhammad Junaid Sanitation Ali Raza Quality control Moin Quality Assurance Kashif Rajab Ali Record keeping 9ABDUL RRAHMAN TAHIR
- 10. MILK CHOCOLATE Production starts with top quality cocoa beans, 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 10ABDUL RRAHMAN TAHIR
- 11. PACKAGING AND STORAGE Chocolate packaged in Aluminum Paper Cardboard Hermetically sealed or wrapped for ultimate convenience The packaging is according to the requirement of market Storage Cool and dry Place 70 F Humidity 55% 11ABDUL RRAHMAN TAHIR
- 12. INTENDED USE Milk Chocolate Dark Chocolate Unsweetened Chocolate White Chocolate Chocolate Milkshakes Chocolate Cakes 12ABDUL RRAHMAN TAHIR
- 13. FLOW CHART Receiving Fermentation Drying 6-7 % moist Cleaning and sorting Roasting the cocoa beans 105 -120 C Winnowing Alkalization K2CO3 Grinding Conching 49-82 C Tempering Molding Packaging Storage 70 F 13ABDUL RRAHMAN TAHIR
- 14. HACCP- 7 PRINCIPLES Conduct Hazard Analysis. 1 Determine The Critical Control Point CCP . 2 Establish Critical Limits. 3 Establish Critical Control Point CCP Monitorin g System. 4 Establish Corrective Action. 5 Establish Verificatio n Procedure s. 6 Establish Document ation. 7 14ABDUL RRAHMAN TAHIR
- 15. HAZARD ANALYSIS PROCESSING STEPS PHYSICAL HAZARD CHEMICAL HAZARD BIOLOGICAL HAZARD 1)RECEIVING Wood, chaff, plant materials pesticides, fertilizers Worms ,insects 2)FERMENTATION Wood pieces Microbes (Salmonella spp ) 3)DRYING Dust , foreign matters mold 4)SORTING AND CLEANING Damage Hygiene - 15ABDUL RRAHMAN TAHIR
- 16. PROCESSING STEPS PHYSICAL HAZARD CHEMICAL HAZARD BIOLOGICAL HAZARD 5)ROASTING Microbial growth due to insufficient roasting 6)WINOWING Dust ,foreign matters in air Polluted air contamination Microbes (contaminated air) 7)ALKALIZATION Chemicals Microbial contamination 8)GRINDING Metals Chemicals from Equipment Microbial contamination 9)CONCHING Metals Microbial Contamination 16ABDUL RRAHMAN TAHIR
- 17. PROCESSING STEPS PHYSICAL HAZARD CHEMICAL HAZARD BIOLOGICAL HAZARD 10)TEMPERING Metal fragments Contamination from poorly maintained Equipment 11)MOULDING Dust particles, plastic materials Uncleaned Moulds 12)PACKING Foreign matter Labelling ink and packaging material 13)STORAGE Improper conditions 17ABDUL RRAHMAN TAHIR
- 18. CONTROL MEASURE AND CRITICAL CONTROL POINT PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL POINT/CONTROL POINT RECEIVING P-sorting C-chemicals free materials B-proper building setting CP1 FERMENTATION P-visual inspection B-proper maintenance of fermentation tanks CP2 DRYING P-visual inspection B-proper maintenance of time and temperature CP3 18ABDUL RRAHMAN TAHIR
- 19. PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL POINT/CONTROL POINT SORTING AND CLEANING P-GMP’s B-Personal Hygiene CP4 ROASTING B-Roasting of cocoa beans in stated period of time and temperature CCP1 WINNOWING P,C,B-use of air filters CP5 ALKALIZATION C-Proper Amount Of Alkalizing Agent B-sanitize the equipment CP6 GRINDING P-visual inspection C-sanitize the equipment B-sanitize the equipment CP7 CONCHING P-Visual inspection B-proper maintenance of equipment CP8 19ABDUL RRAHMAN TAHIR
- 20. PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL POINT/CONTROL POINT TEMPERING P-visual inspection C-Sanitize the equipment CP9 MOLDING P,B-Use of properly maintained molds CP10 PACKAGING P-Use of metal detectors C-Use of appropriate packaging material and labelling ink CCP2 STORAGE P-Maintain Temperature P-Proper handling CP11 20ABDUL RRAHMAN TAHIR
- 21. PROCESS BLOCK DIAGRAM FOR CCP Receiving Fermentation Drying Cleaning and sorting Roasting the cocoa beans Winnowing Alkalization Grinding Conching Tempering Molding Packaging Storage CCP 21CCP ABDUL RRAHMAN TAHIR
- 22. CCP DECISION TREE ROASTING Question 1:Does Roasting involve a hazard of sufficient likelihood of occurrence and severity to warrant its control? yes Question 2:Does a control measure for the hazard exist at this step? yes Question 3:Is control at this step necessary to prevent, eliminate, or reduce the risk of the hazard to consumers? yes CCP Roasted at 105-120ºC Biological Hazard 22ABDUL RRAHMAN TAHIR
- 23. CCP DECISION TREE PACKAGING Question 1:Does Packaging involve a hazard of sufficient likelihood of occurrence and severity to warrant its control? yes Question 2:Does a control measure for the hazard exist at this step? yes Question 3:Is control at this step necessary to prevent, eliminate, or reduce the risk of the hazard to consumers? yes CCP Packaging in Aseptic condition. Physical and Chemical Hazard 23ABDUL RRAHMAN TAHIR
- 24. 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. 24ABDUL RRAHMAN TAHIR
- 25. MONITORING 1)RECEIVING: CHECK :Visual inspection of incoming goods RECORD : Presence or absence of contamination 2)FERMENTATION CHECK : Proper checking of fermentation tanks RECORD : Presence or absence of contamination 3)CLEANING AND SORTING CHECK : Proper personal Hygiene And GMP’s RECORD : Presence or absence of contamination 25ABDUL RRAHMAN TAHIR
- 26. 4)DRYING CHECK :Drying temperature and time RECORD : Temperature and time is noted. 5)ROASTING CHECK : Proper temperature and time for roasting RECORD : Temperature and time is noted 6)WINNOWING CHECK : Personnel hygiene , sanitation of equipment and air filters RECORD : Record any incident of poor personnel hygiene on personnel record 7)ALKALIZATION CHECK : Amount Of Chemicals and sanitation of chemicals RECORD: Amount of Chemicals is noted 8)GRINDING CHECK : Visual inspection RECORD : Record any resulted maintenance 26ABDUL RRAHMAN TAHIR
- 27. 9)CONCHING CHECK : Regular inspection of equipment RECORD : record any resulted maintenance 10)TEMPERING CHECK : Regular inspection of equipment RECORD : record any resulted maintenance 11)MOULDING CHECK: Proper maintenance of molds RECORD : Molding check 12)PACKING CHECK : Visual control And RECORD : Packaging checks 13) STORAGE CHECK : Temperature and storage Conditions RECORD : Storage checks 27ABDUL RRAHMAN TAHIR
- 28. CORRECTIVE ACTIONS 1)RECEIVING Reject contaminated cocoa pods 2)FERMENTATION Provide good condition to avoid microbial attack 3)DRYING Dry the product to stated period 4) SORTING AND CLEANING Maintain personnel hygiene and equipment sanitization 5)ROASTING Roasted to stated time and temperature 6)WINNOWING Provide good quality of air 28ABDUL RRAHMAN TAHIR
- 29. 7)Alkalization Proper chemical check and proper maintenance of equipment 8)GRINDING Proper maintenance of equipment 9)CONCHING Proper maintenance of equipment and material 10)TEMPERING Proper Cooling and heating 11)MOULDING Product will be retained and reworked or discarded 12)PACKING 13) STORAGE Maintain aseptic condition Temperature Control And Proper and proper cleaning of packaging plant storage conditions 29ABDUL RRAHMAN TAHIR
- 30. 30 Verification of HACCP plan after one month Checking for instrument calibration and the reviewing of records Review of CCP records, critical limits, and microbial sampling and analysis procedures System check annually verify monitoring process when system fails 30 VERIFICATION PROCESS ABDUL RRAHMAN TAHIR
- 31. Critical control point records Personnel hygiene records Raw materials records Record any resulting maintenance record Inspection of equipment's record Time-temperature record 31 DOCUMENTATION ABDUL RRAHMAN TAHIR
- 32. DOCUMENTATION Staff training purpose Suppliers in the case of any disputes or problems Customers confidence Food safety inspection Frequency of cleaning equipment 32ABDUL RRAHMAN TAHIR
- 33. CONCLUSION 33 HACCP is related To Food Safety Our product is completely safe due to HACCP Complete HACCP of Industrial Manufacturing Of Chocolate Learn how to make HACCP Plan ABDUL RRAHMAN TAHIR