hazard analysis worksheet(apple juice)

HAZARD ANALYSIS WORKSHEETFRESH EPAL FRUIT JUICE

Ingredient orProcessing step

Potential hazard introduced, controlled or enhanced at this

step

Is this potential hazard is

significant?(YES/NO)

WHYJustification for decision on

previous column

Preventive measures of the significant hazard

Is this step a critical control point

(YES/NO)

1.Farm Growing

BiologicalBird, insect

no Unlikely to occur GAP No

ChemicalPhysical

2.FarmHarvesting

BiologicalDamaged and Rotten apples

yesReduce potential damaged apples

Remove visually mould and it is tree pick apples

Yes

ChemicalChemical contamination pestiside

yesResidue will have adverse effect

CullingGAP

Yes

Physical

3.Farm Bulk storage

BiologicalChemicalMould contamination

noControlled by pre-requisite programs

Temperature <10 C No

Physical

4.TransportationBulk transportation

BiologicalChemicalChemical contamination


GAP No

PhysicalDamaged apples


GAP No

5.Factoryprocurement

BiologicalVegetative and protozoan enteric pathogens (i.e., E.coliO157:H7 andCryptosporidium parvum)

yes Damaged and rotten apples.

Obtain supplier guarantee letter batches containing materials are checked for integrity and order specifications

Yes

ChemicalHigh level of patulin, pestiside

yes May have adverse effect

Supplier guarantee (apples harvested to exclude fallen fruit) and culling or trimming defective (i.e., moldy, rotten, bruised and damaged) apples.

Yes

Physical

6.Factory sorting and washing

BiologicalPathogen growth, contamination yes

to remove rotten apple flesh, and patulin, from the fruit

-Remove visually mouldy apple -using high-pressure water

Yes

Chemical Water’s chlorine level

NoUnlikely occur because of daily in house monitoring on water source supply

tested everyquarter for coliforms by a certified external laboratory

No

PhysicalForeign particles

no To eliminate foreign particles No

7.Factory Milling and pressing

BiologicalPathogen growth

Noprevent a build-up of mouldy apple waste

presses are cleaned regularlyNo

ChemicalChemical patulin contamination


No

PhysicalMetal fragment

no Filteration will trap it No

8.Factory filteration

Biologicalmould yes

Yes

ChemicalChemical patulin

Yes May have adverse effect

PhysicalMetal fragment

yes May have adverse effectScreen are checked and if necessary replace it

Yes

9.Addition of sulphite and water

Biologicalyes

Controlled by pre-requisite programs

ChemicalChemical sulphite, patulin

noAct as preservative

Carried from previous step

Correct weighing andaddition of sulphite

No

Physical Controlled by pre-requisite programs

10.Factory pasteurization


Yes To destroy any pathogens Plate heat exchanger Yes

ChemicalChemical patulin production

YesInactive spore as patulin not destroyed by heat

Yes

Physical

11.Factory aseptic filling



No

ChemicalChemical patulin production


No

Physicalplastic

yesControlled by pre-requisite programs

Yes

12.FactoryStorage & dispatch


yesProduct likely spoils if temperature not controlled well

Maintain coldroom temperature at <18C

Yes

ChemicalN/APhysicalN/A

HACCP Plan Summary

Critical Control Point (CCP)

Process step

Hazard to be

addressed in

HACCP plan

Critical limits for each control measure

MonitoringCorrective

actionVerification Records

What How frequency who

CCP1Farmharvesting

Mould

<1% visibly mouldy apples

Remove mouldy and damaged applesAvoid trash and soil contamination

Visual observation

Each harvest

Trained supervisor

Discard

Sampling to determine characteristic quality of apples

Farm record

CCP2

Factorysorting and washing

Mould and patulin

-<1% visibly mouldy apples

-Critical soaking time and pressure of spray system

-Remove mouldy apples

-Leach patulin from apples. Remove rotten parts of fruit containing patulin with pressure spraying

-Visual observation of samples

-Time of soaking step; regular check of water spray pressure

Twice per production run

Quality control staff

-Discard or re-sortAdjust inspection procedure

-Repeat the washing step

-QC managerReview allrecords withinone week ofpreparation

-Sample forpresence ofpatulinquarterl

-Operator log % reject

-Factory record

CCP3 Filtration

Patulin, mould

Metal fragment

Size and quality of particles remainingScreen is intact

Remove patulin in particles

Integrity of the screen

Laboratory test

visual

Every batch

daily

Production emplyee

Un-block /replace filterRe-filter juice

Remove the metal or if necessary replace the screen

Review screens monitoring record

Review maintenance record

Factory record

CCP4Addition of sulphite and water

Shelf live and pathogen contamination

Act as preservative

pathogen contamination in acceptable level

Reduce pathogen level

Laboratory test

Every batch

Productionemplyee

Check and monitor amount of the sulphite added

Quality assurance personel review the record of samples

Factory record

CCP5pasteurizations

Mould

patulin

-Correct time/Temperature

->160 F for6 s

Temperature of the juice

- Set pump speed to 5 to deliver > 6 s

-Automated readout temperature recorder

Visualcheck ofpositivedisplacementpump atset speed

-Continuousrecordingwith hourlyvisual checkof record.

-Daily at beginningofproduction

Pastuarise operators

Re-pasteurise? and adjust the temperature

Adjust the pump to deliver > 6 s

Clean and sanitizeall equipmentpost-pasteurization

Verification of the heat process

Calibration of the pump

Factory record

Temperature record

CCP determination

Process step Hazard

Question 1Do preventive measures

exist?No- not a CCP

However, if preventive control measures are

required to ensure safety then modify step, product

or process.

Yes – to Q2

Question 2Is the step

specifically designed to eliminate or reduce

the likely intake occurrence of the

hazard to an acceptable level?

No – to Q3Yes - CCP

Question 3Could

contamination with identified

hazards occur in excess of

acceptable levels?

No – not a CCPYes – to Q4

Question 4Will a subsequent

step eliminate identified hazards

or reduce the likely occurrence to an

unacceptable level?

No – CCPYes – not a CCP

CCP

Yes or no

FarmHarvesting

Mould Yes Yes Yes

Factorysorting and washing

Mould and patulin

Yes Yes Yes

FiltrationPatulin, mould

Metal fragmentYes Yes Yes

Addition of sulphite and water

Shelf live and pathogen contamination

Yes No Yes Yes Yes

pasteurizations Mould, patulin Yes Yes Yes

hazard analysis worksheet(apple juice)

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