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P ti C d 2Presenting Code 2CODE OF GOOD MANUFACTURING
PRACTICES (CoP)
F P l Oil MillFor Palm Oil Mills
By Ir. N.Ravi Menon,
MPOB
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1. WEIGHING BRIDGE
1 Scope Food Product Application
2 Objective Maintain accuracy
3 Principles Average error< 0 3%3 Principles Average error< 0.3%
4 Criteria Yearly calibration & certification
5 Indicators Document related data
6 Verifiers Audit-internal/external
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2. FFB Hoppers& Apron
1 Scope Food Product Application
2 Objective Unload FFB in hopper not on apron. Keep them clean. First in first out
3 Principles Prevent bruising of bunches & FFA3 Principles Prevent bruising of bunches & FFA rise. Food safety-cleanliness
4 Criteria FFA<5% Visual inspection, CCTV
5 Indicators Documentation of FFA analyses
6 Verifiers Audit-internal/external
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3. FFB GRADING
1 Scope Food Product Application
2 Objective Receive only good quality FFB
3 Principles To ensure good extraction and quality3 Principles To ensure good extraction and quality products
4 Criteria FFA < 5%, DOBI > 2.3% in CPO. Reject off-quality crop, loose fruits >8%, zero contamination in FFB
5 Indicators Production book, Lab records, buyer’s 5data on quality.
6 Verifiers Audit-internal/external
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4. FFB UNLOADING FACILITY
1 Scope Food Product Application
2 Objective Prevent bruising of FFB
3 Principles Ensure hopper space for FFB storage3 Principles Ensure hopper space for FFB storage
4 Criteria Minimum 8 hours storage space
5 Indicators CCTV Zero dumping on hopper apron
6 Verifiers Audit-internal/external
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5. CAGE FILLING
1 Scope Food Product Application
2 Objective To prevent spillage resulting in bruising of fruits.
3 Principles Bruising results in a rise in FFA- CPO3 Principles Bruising results in a rise in FFA CPO quality deterioration
4 Criteria Single point filling reduces this
5 Indicators Routine inspection for spilled fruit
6 Verifiers Audit-internal/external
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6. CAGE MATERIAL
1 Scope Food Product Application
2 Objective Prevent iron & copper contamination of CPO by using Stainless steel material
3 Principles Mild steel causes oxidation of CPO3 Principles Mild steel causes oxidation of CPO
4 Criteria Quality deterioration of CPO
5 Indicators DOBI analyses of CPO
6 Verifiers Audit-internal/external
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7. STERILIZER CONSTRUCTION/ DESIGNDESIGN
1 Scope Food Product Application
2 Objective Prevent iron contamination by lining sterilizer with s/s or ceramic material
3 Principles Iron in CPO promotes oxidation
4 Criteria Quality deterioration of CPO4 Criteria Quality deterioration of CPO
5 Indicators DOBI value of CPO5
6 Verifiers Audit-internal/external
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8. STERILIZATION.
1 Scope Food Product Application
2 Objective To ensure by good de-aeration by continuous bleeding of condensate
3 Principles Air is an insulator that prevents heat3 Principles Air is an insulator that prevents heat transfer into bunches
4 Criteria To ensure 100% FFB stripping.
5 Indicators Stripping efficiency- % Un-stripped bunchesbunches
6 Verifiers Audit-internal/external
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9.STERILIZATION CONDENSATE
1 Scope Food Product Application
2 Objective Stop sterilizer condensate recycling to prevent CPO contamination
3 Principles To reduce oxidation of CPO3 Principles To reduce oxidation of CPO
4 Criteria To maintain quality of CPO
5 Indicators DOBI check and metal content in CPO
6 Verifiers Audit-internal/external
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10.STERLIZED BUNCH ELEVATOR
1 Scope Food Product Application
2 Objective To prevent fruit contamination with grease
3 Principles Grease/lubricant contamination lowers3 Principles Grease/lubricant contamination lowers the quality of CPO
4 Criteria Grease is hydro carbon not allowed in food products unless vegetable based.
5 Indicators Test for hydro carbon contamination
6 Verifiers Audit-internal/external
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11.OVERHEAD HOIST/ TIPPER/THRESHERTIPPER/THRESHER
1 Scope Food Product Application
2 Objective To prevent fruit contamination with grease
3 Principles Grease/lubricant contamination lowers the quality of CPO
4 C it i G i h d b t ll d i4 Criteria Grease is hydro carbon not allowed in food products unless vegetable based.
5 Indicators Test for % hydrocarbon in CPO
6 Verifiers Audit internal/external
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6 Verifiers Audit-internal/external
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12. DIGESTER CONSTRUCTION
1 Scope Food Product Application
2 Objective Prevent iron contamination by lining digester with s/s or ceramic material
3 Principles Iron in CPO promotes oxidation3 Principles Iron in CPO promotes oxidation
4 Criteria Enhance quality of CPO
5 Indicators DOBI value of CPO
6 Verifiers Audit-internal/external
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13.DIGESTION OPERATION
1 Scope Food Product Application
2 Objective Maintain ¾ full, Least gap between arms and the body, temperature>90oC. Ensure maximum digester drainage
3 Principles For good digestion-promotes cell rupture, reduce oil loss
4 Criteria Extract maximum oil minimum oil loss4 Criteria Extract maximum oil- minimum oil loss
5 Indicators Lab tests5
6 Verifiers Audit-internal/external
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14. PRESS CONSTRUCTION/OPERATIONCONSTRUCTION/OPERATION
1 Scope Food Product Application
2 Objective Prevent iron contamination by hard facing press screws to reduce wear
3 Principles Iron in CPO promotes oxidation
4 C it i Q lit d t i ti f CPO4 Criteria Quality deterioration of CPO
5 Indicators DOBI value of CPO5
6 Verifiers Audit-internal/external
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15. VIBRATING SCREEN/ CRUDE OIL TANK/PUMPSTANK/PUMPS
1 Scope Food Product Application
2 Objective Ensure good screening of tailing from CPO
3 Principles Solids in CPO obstructs oil separation from crude
4 C it i I d il t ti4 Criteria Improved oil extraction
5 Indicators Lab analysis for oil loss in waste water5 y
6 Verifiers Audit-internal/external
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16. CRUDE OIL TANK
1 Scope Food Product Application
2 Objective Ensure least iron contamination of CPO
3 Principles To reduce oxidation of CPO3 Principles To reduce oxidation of CPO
4 Criteria To maintain CPO quality
5 Indicators Lab analysis for oil loss in waste water
6 Verifiers Audit-internal/external
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17. CRUDE OIL PUMPS
1 Scope Food Product Application
2 Objective To prevent emulsification of CPO by using positive displacement pump
3 Principles Difficult to separate emulsified oil3 Principles Difficult to separate emulsified oil
4 Criteria Reduce oil loss in waste water
5 Indicators Lab analysis for oil loss in waste water
6 Verifiers Audit-internal/external
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18. CLARIFICATION PROCESS
1 Scope Food Product Application
2 Objective Maintain temperature > 90o C
3 Principles At high temperature least viscosity and3 Principles At high temperature least viscosity and best separation
4 Criteria Better oil extraction
5 Indicators Lab analysis
6 Verifiers Audit-internal/external
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19. CLARIFICATION TANK
1 Scope Food Product Application
2 Objective Use non ferrous material or s/s for lining to reduce iron contamination
3 Principles To reduce oxidation of CPO3 Principles To reduce oxidation of CPO
4 Criteria To maintain quality of CPO
5 Indicators Lab analysis for iron and DOBI values
6 Verifiers Audit-internal/external
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20.OIL PURIFICATION & DRYING
1 Scope Food Product Application
2 Objective Ensure > 700 mm vacuum to ensure good drying of CPO
3 Principles To maintain low moisture & dirt level in3 Principles To maintain low moisture & dirt level in production CPO
4 Criteria Maintain moisture <0.15%, dirt < 0.015 to ensure product quality
5 Indicators Lab analysis
6 Verifiers Audit-internal/external
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21. CUDE PALM OIL STORAGE
1 Scope Food Product Application
2 Objective Maintain temperature below 50oC by automatic temperature control system
3 Principles To reduce oxidation of CPO3 Principles To reduce oxidation of CPO
4 Criteria To maintain quality of CPO
5 Indicators Lab tests DOBI values
6 Verifiers Audit-internal/external
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22. CPO STORAGE TANK
1 Scope Food Product Application
2 Objective Must be coated, bottom 3 meters with epoxy, s/s, ceramic or linseed oil
3 Principles Reduce iron pick up by CPO3 Principles Reduce iron pick up by CPO
4 Criteria Iron causes oxidation of oil
5 Indicators Lab tests for DOB, iron content
6 Verifiers Audit-internal/external
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23. CPO TRANSPORTATION
1 Scope Food Product Application
2 Objective Tanks must be clean and sterilized with hot water
3 Principles To prevent entry of microbes into CPO3 Principles To prevent entry of microbes into CPO
4 Criteria CPO must be free from microbes-traceability – marketing tool
5 Indicators
6 Verifiers Audit-internal/external
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24. SLUDGE HANDLING
1 Scope Food Product Application
2 Objective Oil from sludge must not be recycled into process line
3 Principles Causes introduction of microbes3 Principles Causes introduction of microbes
4 Criteria CPO must be free from microbes-traceability – marketing tool
5 Indicators Test for microbes on a routine basis
6 Verifiers Audit-internal/external
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25. KERNEL DRYING PROCESS
1 Scope Food Product Application
2 Objective Ensure kernel drying with hot air at 70o
C for a minimum of 14 hours
3 Principles Kernel heating must ensure a moisture3 Principles Kernel heating must ensure a moisture level < 7%.
4 Criteria To prevent the kernel from being moldy
5 Indicators Analysis of kernel dryness
6 Verifiers Audit-internal/external
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26. KERNEL STORAGE
1 Scope Food Product Application
2 Objective Must be stored in silos, bunkers or bags and never dumped on floor
3 Principles Danger of microbial contamination by3 Principles Danger of microbial contamination by dogs, cats, rats, birds etc
4 Criteria Kernel must be free from microbes-traceability issue loss of market
5 Indicators Management policy and strict implementation Regular checksimplementation. Regular checks
6 Verifiers Audit-internal/external
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27. NUT CRACKING PROCESS
1 Scope Food Product Application
2 Objective Broken kernel must be as low as possible by using good nut crackers
3 Principles Broken kernel subject to microbial3 Principles Broken kernel subject to microbial contamination
4 Criteria Food safety to be maintained to enhance marketability of kernel products
5 Indicators Regular lab analyses for nicrobes5
6 Verifiers Audit-internal/external
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28. ENVIRONMENT
1 Scope Food Product Application
2 Objective Boiler smoke emission to conform to DOE limits
3 Principles Will cause pollution of atmosphere3 Principles Will cause pollution of atmosphere
4 Criteria Detrimental to health and well-being of people
5 Indicators Lab results and DOE checks
6 Verifiers Audit-internal/external
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29. PALM OIL MILL EFFLUENT
1 Scope Food Product Application
2 Objective BOD of effluent to meet DOE limits all the time
3 Principles To prevent endangering eco systems3 Principles To prevent endangering eco systems and water contamination
4 Criteria Global requirement to preserve eco system
5 Indicators Analysis on a routine basis
6 Verifiers Audit-internal/external
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