FACULTY SCIENCE AND TECHONLOGY

JANUARY / 2020

XBFS4103

FOOD SAFETY AND HEALTH

MATRICULATION NO: 970423105056-001

IDENTITY CARD NO. : 970423-10-5056
TELEPHONE NO. : 018 – 231 3711
E-MAIL : [email protected]
LEARNING CENTRE : SHAH ALAM

1
TABLE OF CONTENTS

1.0 Introduction ..........................................................................................3-5

1.1 Introduction to GMP
1.2 Introduction to HACCP

2.0 Product Description................................................................................6

3.0 Process Flow Diagram..........................….............................................7-8

4.0 GMP Plan...............................................................................................9-12

5.0 HACCP Plan.........................................................................................13-18

6.0 Conclusion.............................................................................................19

REFERENCES.......................................................................................................20-21
1.0 Introduction
Food safety is a huge concern nowadays, causing healthcare organizations and
governments in many countries to find ways to monitor production chains. It is
necessary for quality management methods to be implemented in this situation. These
methods will focus on product and process standardization, product traceability and
food safety assurance. A combination of good manufacturing practices (GMP),
sanitation standard operating procedures (SSOP), and a hazard analysis and critical
control point (HACCP) program is the foundation of the food safety system to be
implemented in the food industry.

1.1 Introduction to GMP

Good Manufacturing Practices (GMP) is a legal and moral obligation for any
businesses in the food industry to manufacture food that is safe to consume for the
public. Otherwise, the company will most likely to face serious consequences by not
enforcing the GMP. Everyone who is working in the food industry should be educated
and trained on the GMP procedures. These regulations which is imposed by the FDA,
aim to limit the occurrences of product recalls, adverse effects and potential lawsuits
that may result from unsafe products [ CITATION Gue15 \l 1033 ]. GMP as described
in the Code of Federal Regulations under Title 21, Part 110 by the Food and Drug
Administration are the minimum sanitary and processing criteria for food
manufacturers. GMP regulations outlines general measures to ensure that processes
necessary for production and testing are clearly defined, validated, reviewed, and
documented, and that the personnel, premises and materials are suitable for the
production.

GMP is based on four specified criteria, including work standards, manufacturing

infrastructure, equipment and utensils, and production and process controls.

i. Personnel practices
GMP's guidelines with workers will include disease prevention,
cleanliness, preparation and inspection. It's important that all workers are
educated and skilled to do the job [ CITATION Safnd \l 1033 ]. They
should be knowledgeable of GMP guidelines and receive further training
and lessons on sanitation, and other information related to their job. For
 each worker, the corresponding supervisors should be transparent on job
requirements to prevent confusions and reduce the risk of issues such as
overlapping roles.
Personnel in the production area will also need to put into practice many
things related to cleanliness such as wearing outer clothing, personal
hygiene, washing hands, avoiding accessories, wearing gloves
and hairnets, keeping personal possessions, avoiding alcohol, nicotine and
make-up from food manufacturing area [ CITATION UNLnd \l 1033 ].

ii. Building and Facilities

The building and its facilities should be designed to promote smooth
operation, activity, washing, inspections and repairs[ CITATION Pro15 \l
1033 ]. The building should be located in an area that is ideal for their
operations and free from the risks of materials and products being
contaminated. The building should also be designed to prevent technical
mistakes and need to be easy to clean and maintain [ CITATION Safnd \l
1033 ]. Other than that, having adequate lighting and ventilation is vital in
the building.

iii. Equipment and utensils

All equipment and utensils used to facilitate effective cleaning and
maintenance must be designed with good material and quality. Equipment
used for monitoring crucial parameters such as pH, temperature, and water
activity had to be precise and maintained accordingly [ CITATION UNLnd
\l 1033 ].

iv. Production and process control

The production and process control section have two primary subdivisions:
(a) raw materials and other ingredients;
(b) manufacturing operations.
The first subsection includes details of the necessary inspection, storage,
and ingredient handling[ CITATION UNLnd \l 1033 ]. Relevant
information about the treatment of microbiologically active ingredients
and the handling of aflatoxin or other toxins related ingredients is given.
 There are also guidelines for the handling of frozen raw materials and
ingredients, for both bulk liquid and dry ingredients[ CITATION UNLnd \l
1033 ]. Subsection of manufacturing operations includes conditions and
controls required to reduce the risk for microorganism growth, or food
contamination. For the control of conditions, it is important to manage
factors namely time, temperature, humidity, water activity, pH, pressure
and flow rates [ CITATION UNLnd \l 1033 ]. Other than that, this
subsection also explains basic storage and delivery requirements. This
includes the storage and delivery of finished products under requirements
that protect against physical, chemical and microbial
contamination[ CITATION FDA04 \l 1033 ]. The container and the food
always have to be protected from deterioration.

1.2 Introduction to HACCP

Hazard Analysis and Critical Control Point (HACCP) is defined as the safety
and quality management tools created by Pillsbury Corporation in the 1960s (Bennet
and Steed, 1999). The HACCP system is associated with food safety management.
This is a program that defines, analyses and manages risks that are relevant to food
safety[CITATION Pro15 \l 1033 ]. It consists of comprehensive list of practices used
to monitor production of food with a goal in ensuring food safety and preventing
changes in foodstuffs. HACCP is focused on the idea that hazards impacting food
safety can either be removed or reduced by prevention during production rather than
by final product inspection[ CITATION Pro15 \l 1033 ]. This way, it can eliminate
hazards in the food chain from the earliest level. The HACCP system can be
implemented immediately from harvest to consumption level.

HACCP is a food safety assurance system that controls the biological,

chemical and physical hazards by using 7 principles. The following steps are used in a
HACCP system (Prof Gulam, 2015):

i. Recognize the risks that are necessary to avoid, remove or reduce

ii. Recognize the crucial control points that are necessary for avoiding,
removing or reducing a hazard.
 iii. Develop and apply appropriate procedures for controlling important
control points
iv. Develop corrective actions when monitoring
v. Develop methods to evaluate the effectiveness of the whole program
vi. Record your work on food safety
2.0 Product Description

Canned Sardine Species included:

 Sardina melanostictus
 Sardinella caeruleus
 Sardinops neopilchardus
 Sardinops sagax

Name of the product: Sardine Sedap

Ingredients: Wild caught sardines fish, tomato paste, sustainable palm oil (rspo
certified), salt, contains thickener (xanthan gum) as permitted food conditioner,
pepper and Mono Sodium Glutamate (MSG)

Product Canned sardines in tomato sauce

Contents Beheaded tail-off sardines: 75%
Tomato Paste: 22%
Palm oil: 2%
Salt: 1%
pH: 5.8-6.1
water activity a w : 0.98 (high moisture)
How the product is To be eaten with or without further cooking
to be used
Packaging 2 pieces round aluminium can, easy open lid. Airtight sealed
metal container.
Shelf life 3 years at ambient temperature
Where the product Retail, institutions and food service. Could be consumed by
will be sold high-risk groups (infirm, immunocompromised, elderly)
Labelling The product is not suitable for people with allergies or
instructions intolerances
Special distribution No physical damage, excess humidity or temperature
 control extremes

3.0 Process Flow Diagram

① Fish Receival Chill room

Cut off the head and tail

and gutting of the fish

Preparation
② Brining
of brining

Rinse and Clean

Empty cans Inspection Fill cans with sardines

and washing
Rinsing

Loading trays

Cooking

Draining of excess liquid

and drying

Tomato Paste Preparation ③ Hot Filling Heating Oil, brine,

40 40 water
−60 ℃ ④ Can Seaming −60 ℃

Washing of cans

⑤ Sterilization

⑥ Cooling of cans

⑦ Labelling and cartoning

Palletization and ⑧storage

Despatch
Critical Control Point Critical Limit
1. Fish Receival Fish T< 6ºC
TVB <250 ppm
Histamine < 50ppm
2. Brining 16 - 18ºC Baume
3. Hot Filling No Under/over filled or wrong sauce
4. Can Seaming No leaking container
5. Sterilization F0 = 7–14 minutes, generally > 10
minutes
Sterilization Temperature = 122.5ºC, with
an overshooting at 123.5ºC
6. Cooling sterile cans - Residual free chlorine 1 ppm
- Duration of cooling < 1 hour
7. Labelling & Cartoning - No wrong Label or Carton
- Label that is legible and contains a
listing of correct ingredients
8. Storage of the finished product T < 40ºC
4.0 GMP Plan

1. Plants and grounds

A food manufacturing plant should include (Troller, 1993):
 sufficient space for machinery, installations and materials storage
 division of different operations to prevent cross contamination
 sufficient lighting and ventilation
 protection from pests.

Food industry design is planned out with simple, ideally 'straight through' lines
of product flow which is considered to be the most effective (Hayes, 1992). In order
to prevent cross-contamination from raw materials, final or intermediate processes
must be separated to minimize the risk of a semi-processed product being
decontaminated. Time and temperature parameters are highly important as Critical
Control Points (CCPs) for products during manufacturing to prevent growth of
bacteria. It ensures a constant and continuous flow of all products is needed to fully
monitor such a critical factor [ CITATION Hus03 \l 1033 ]. When any product flow
delays are required, the products should be kept refrigerated. Other than that, it is
important that the processing areas should be physically divided by appropriate walls
of both the raw materials and other products[ CITATION Hus03 \l 1033 ]. The
movement of workers between the separate processing areas should be use of
allocated coloured clothing set by the management. There should be no human traffic
in these areas and any equipment used in unclean areas should never be used in clean
areas.

2. Personnel Practices
All workers will undergo documented training on personal hygiene, protocols for
washing and disinfection, material handling and safety, HACCP-system and process
control [ CITATION Hus03 \l 1033 ]. The overall training program will include
frequent refresher training. Training in proper food hygiene is crucial. In addition,
regular monitoring and checking during working hours will ensure successful
implementation of methods learned during training. The workers need to be informed
of the significance and importance of their actions in making a contribution to the
GMP system. All workers should be aware of their roles and duties in protecting food
from contamination

3. Building Facilities
In a seafood manufacturing plant, the necessary facilities are [ CITATION Hus03 \l
1033 ]:
• sufficient supply of power
• sufficient supply of water; When required, hot water and steam must be made
accessible for cleaning and sanitation
• a proper water treatment system (chlorination plant, waste water treatment plant)
• proper washing and disinfecting equipment
• sufficient worker accommodation (washing facilities, toilets, staff rooms).

Appropriate hand-washing stations must be installed at the entrance to the processing

areas and in all processing areas where it requires workers to wash and clean their
hands[ CITATION Hus03 \l 1033 ]. They must be provided with hand-cleaning and
efficient disinfection supplies and towels for single use or other hand-drying
appliances. Sufficient toilet facilities must be available, properly situated, (no direct
access to processing areas) and maintained in a hygienic condition and good repair.

4. Equipment and utensils

In the food industry a wide number of utensils are used. Specifically, all food that has
contact with surfaces such as utensils, knives, plates, cutting boards, boxes and bins,
conveyor belts, gloves, and aprons, need to be thoroughly cleaned, disinfected and
maintained, to prevent contamination of the product[ CITATION Dud18 \l 1033 ].
Apart from that, the surfaces must be made of non-toxic, non-absorbent material that
is resistant to the environment, the food, cleaning and disinfecting chemicals. Food
contact materials that should be avoided are: wood, ferrous metals, brass and
galvanised metals. One of the biggest obstacles of industrial food safety is equipment
design. A large number of new machines and equipment are designed and installed
without careful attention to the fact that cleaning and sanitizing of these equipment is
necessary[ CITATION Dud18 \l 1033 ]. It should function in accordance with its
intended use and facilitate good hygiene practices, including monitoring.
 5. Process Control
Temperature and time are also critical in hindering oxidation and spoilage of
chemicals (Huss 1994). Fish is considered one of the most perishable foodstuffs.
Packing in ice is used to keep the fish cool; this technique is used to decrease the
temperature to around 0 ° C, minimizing the development of spoilage and pathogenic
microorganisms, thus decreasing the spoilage rate and minimizing or removing other
safety risks. In addition, it will slow the decay of the fish during fish handling and
processing in fisheries industry. Effective chilling techniques on board the fishing
vessels and on the shore lead to higher quality fish that is, on landing (Garthwaite,
1992).

Temperature and time parameters are critical for deterring the growth of pathogenic
bacteria, histamine producing bacteria and spoilage bacteria at any stage from
catching the fish to distribution of the fish product [ CITATION UKD18 \l 1033 ].
Minimizing bacterial contamination of the fish at all processing stages is important.
When arrived, dirt should be cleaned off the fish, and the surfaces of which the fish
come into contact should be kept in clean condition. The properly iced fish can cool
fast and retain quality for 1 to 2 weeks, depending on the species. Ease handling,
weight loss reduction, and bruising prevention are positive effects to be considered for
short-term storage of refrigerated seawater (Shapton, 1991).

6. Sanitary Operations
The food manufacturing unit must develop efficient systems to [ CITATION Dud18 \l
1033 ]:
• Provide sufficient and appropriate inspection and cleaning
• Control pests
• Manage waste
• Review the overall effectiveness of inspection and cleaning procedures

Facilities and equipment shall be maintained in an appropriate state of repair and

condition to allow all sanitation procedures. Cleaning shall remove remnants of fish
and dirt which could be a source of contamination. Cleaning procedures needs to
ensure thorough washing of all areas of the facility, including sanitation of washing
appliances [ CITATION Hus03 \l 1033 ]. The processing area is cleared of remaining
products, spills, containers and other loose items. Machines, conveyor belts, etc. are
dismantled to allow thorough cleaning and disinfection to all areas where
microorganisms can accumulate [ CITATION Hus03 \l 1033 ]. Electrical equipment
and other critical devices should be covered from water and the chemicals used during
the cleaning procedures.

7. Warehousing and distribution

The storage and transportation conditions should be as such to eliminate the
contamination and fish damage. Storage rooms and vehicles used to transport fish and
must also be clean. They must provide the fish with protection against contamination
from dust and exposure to higher temperatures. They need to provide protection to the
fish against any contamination and exposure to higher temperatures. Vehicles must be
equipped with refrigeration to preserve the fish at 0 ° C (chilling) or 18 ° C (freezing)
where possible [ CITATION Hus03 \l 1033 ]. In addition, the packaging design and
materials must ensure sufficient protection to avoid contamination.
5.0 HACCP Plan
There are seven HACCP principles that need to be applied and incorporated in
every food industry worldwide. These principles include hazard analysis, CCP
identification, establishing critical limits, monitoring procedures, corrective actions,
verification procedures, and record-keeping and documentation. According to these
systems, if there is a deviation indicating a lack of control, the deviation is identified
and necessary steps are taken to restore control in a timely manner to ensure that
potentially harmful products do not reach consumers.

Principle 1: Conduct a hazard analysis.

Determine hazards in food safety and define preventive steps to monitor such hazards.

Principle 2: Determine the critical control points (CCPs).

A critical control point is a step wherein control can be introduced, which is necessary
to avoid, remove or minimize a food safety hazard to an acceptable level. These will
be the points in the food processing which may pose the greatest risk.

Principle 3: Establish critical limits.

Control points require critical limits. These limits must be met, which include both
minimums and maximums. Any limit breaches will need to be discussed and dealt
with.

Principle 4: Establish monitoring procedures.

This monitoring standard is set up to ensure that all changes that might lead to risk are
recorded and monitored at all important control points. Critical limits will also be
monitored during this principle.

Principle 5: Establish corrective actions.

A strategy for immediate corrective measures would be in place should a hazard occur
at a critical control point . This could include a critical limit minimum not being met,
or alternatively, a critical limit maximum being overtaken.
Principle 6: Establish verification procedures.
A set of procedures should be set forth in order to ensure HACCP is always followed
and implemented correctly in the food manufacturing workplace. All employees
involved in the process should be able to verify the steps for which they are
responsible.

Principle 7: Establish record-keeping and documentation procedures.

All plants are required to maintain certain documents, including its hazard analysis
and written HACCP plan, and records documenting the monitoring of critical control
points, critical limits, verification activities, and the handling of processing deviations.
Process Hazard CC Control Critical Limit Monitoring Corrective Action
Step P Measure Procedure Freq Respon- Activity Respon-
-uency sibility sibility
Fish Spoiled fish 1 Proper fish icing Fish T<6ºC Fish sorting Every Supervisor Report to Operator
Receival or fish with and handling TVB<250 ppm according to Batch QC Supervisor
high after landing, Histamine < freshness. Check manager
histamine refrigerated 50ppm the temperature,
levels transportation use correct
chemical method
and perform
spectrofluorimetric
Brining Spoilage, 2 Correct Temp<5ºC Fish to be stored in Every Supervisor Report to Operator,
temperature and
insufficient / before brining chiller until brined. Batch QC Supervisor process
Brine conc./time
excess salt Temp – manager Reject any fish manager
16-18ºC Brine make-up and out of temp or
Baume during dip time recorded out of spec
brining on production brined.
record.
Hot Under/over 3 Check weigh Product net Operator monitors Every Supervisor Report to Operator
Filling filled and recipe weight average product weights as Batch Supervisor
 Wrong control =>declared, procedure
Sauce no pack<95% Re-adjust
of declared- Checks sauce sauce weight;.
upper average correct for
weight. not production plan
exceeded,
sauce matches
the can code
Can Post-process 4 Training of the No leaking Can seams Every Can Container Operator,
Seaming contamina- can seaming cans monitored 30 seaming integrity Process
tion, supervisor of according to minutes Operator records Manager
incorrect production. procedure. (forms 2+4)
code
Seam checks Can code checked
and can code at start of
checks production.

Sterili- Bacterial 5 Regular F0 = 7–14 Retort Operator Twice a Retort Identify cause Retort
zation Growth maintenance of minutes, ensures crates have year Operator of deficiency Operator
(under- the retorts. generally > 10 thermal tags and as
 process) Training of the minutes. applied and needed QC Repair the
Quality retort operating Sterilization retorted in Manager retort
defect (over- supervisor. Temperature = accordance to Every
process) 122.5ºC, with procedure. retort
an over- cycle
shooting at
123.5ºC

Cooling Microbial 6 Chlorination of Residual free Operator monitor Every Retort Identify lot and Retort
Sterile contamina- cooling water. chlorine 1 ppm chlorine level and day Operator desterilize Operator
Cans tion duration of cooling
Cooling time < Duration of Every QC Isolate lot and
Thermo- 1hour cooling < 1 retort manager check for
philic hour cycle thermo-philic
spoilage spoilage

Label- Wrong 7 Provide label No wrong Operator checks Every Supervisor Hold product Operator
ling and Label that is legible Label or labels, cartons, can Batch QC for
Carto- Wrong and contain a Carton codes and carton Manager relabelling
ning Carton listing of correct codes match /cartoning as
 ingredients appropriate.

Storage Thermo- 8 Storage at T <40ºC Operator always Daily Storage Isolate lot and Operator
of the philic T <40ºC monitor and record Supervisor check for
finished spoilage the temperature thermophilic
product spoilage
6.0 Conclusion

It has been advised that HACCP and GMP be implemented as a solution to eliminate
or reduce any potential hazards in seafood products (Bagumire et al., 2010) as well as
ensuring food safety and reducing foodborne diseases. Apart from that, improving and
applying HACCP and GMP by testing, regulating and monitoring the processing and
distribution of seafood is highly encouraged, because it can influence the safety of
seafood products processed for consumption of the public (Okonko et al., 2009).

(3153 words)
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