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Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
Engineering/Production Mgr.
Microbiology/QC Mgr. Chemistry/Warehouse Mgr.
Name of product Composition Product characteristics Methods of processing Methods of preservation Primary packaging Conditions of storage Method of distribution Shelflife Specific labelling Instruction on the label
: cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu ::-
Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients
Storage at 5-150 C
Fermentation 2 (27-300 C)
Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Description of Hazard
Contaminated yeast (by spoilage or pathogenic m.o.)
Insects
B P
Storage of egg
Weighing of all ingredients Mixing of sugar, salt, skim milk
B
P P
Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items
Adding egg and shortening Adding wheat flour, yeast and cold water
Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces
Blending
B
P B
Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air
Fermentation 1
Fermentation 2
Description of Hazard
Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o.
Baking
Cooling
Filling with cream
B
B
Packaging
Storage
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
Description of Hazard
-
B C -
Mixing
Beating Storage
P
P B
Personal item
Personal item Growth of spoilage m.o.
Potential Hazard(s) Preventive or Control B/C/P Description of Hazard Measures B Contaminated yeast (by spoilage Quality assurance (certificate of or pathogenic m.o.) analysis) from supplier P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs 0 B Growth of pathogenic bacteria Refrigerated storage (5-15 C), Label expired date. P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Eggshell Inspection of the ingredients (cracked eggs) P Insect bone pieces Filtering of wheat flour B Contamination of spoilage m.o. SSOP from the air P Personal item SOP for production area (no personal items are wore) B Contamination of spoilage & SSOP pathogenic m.o. from the air & worker
Process Step Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage Receiving jelly mallow, butter, shortening Storage
Preventive or Control Measures SSOP SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
P P B
B/C/P B
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water
Storage of egg
Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items
h l
M L
Y N
Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date.
Inspection of the ingredients, SOP for production area (no personal items are wore)
B/C/P P
Insect bone pieces Contamination of spoilage m.o. from the air Personal item
Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air
SSOP
m l
M L
N N
SOP for production area (no personal items are wore) SSOP
Fermentation 1
SSOP
Cooling
B
B B
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
m
m m
H
H M
Y
Y N
SSOP
SSOP Proper storage condition (dry, clean), expired date must be stated on the label
B C
m m
H H
Y Y
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients -
Mixing
Beating Storage of cream
P
P B
Personal item
Personal item Growth of spoilage m.o.
l
l m
M
M H
N
N Y
SSOP
SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
P1
Y
P2
Y
P3
N
CCP?
N
P B
P B B C
Y Y
Y Y Y Y Y Y
Y Y
Y Y Y N N Y
N N
N N N N
N N
N N N Y Y N
Water
P B
Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg
Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening
CCP
B P B
P P P
N Y N
N N N
Y -
N -
Y -
N -
N CCP N
N N N
B P
N N
N N
P1 N
N N N Y
P2 Y
P3 N
P4 Y
P5 Y
CCP? N
N N N N
Baking
Cooling Filling with cream
B
B B
N
N Y
N
N CCP
Packaging
Storage and distribution of bread
B
B
Y
N
Y
-
N
-
Y
-
N
-
CCP
N
Receiving egg
4 (P)
5 (B)
6 (B) 7 (B) 8 (C)
Storage of cream
9 (B)
Every day
1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr.
Receiving egg
Time : 1. Disposition of non-complying every 10 products minutes 2. Correct the cause to prevent T : Every 6 recurrences hours 3. Maintain record 4. Write a report to QA mngr.
Time : 1. Disposition of non-complying Every 10 products minutes 2. Correct the cause to prevent T : Every 6 recurrences hours 3. Maintain record 4. Write a report to QA mngr.
Packaging of bread
Monitoring Procedures Corrective Actions How Where Who Frequency Measure Warehouse Warehouse Every day 1. Disposition of non-complying temperature, Warehouse mngr. ingredients check label 2. Correct the cause to prevent recurrences 3. Maintain record Warehouse Every day 1. Disposition of non-complying mngr. products 2. Correct the cause to prevent recurrences 3. Maintain record
Storage of cream
Receiving egg
4 (P) Cracked/broke Cracked/bro Inspection of Receiving Receiving Every 1. Rejection of non-complying ken eggs site personnel receiving ingredient n egg = 0 incoming eggs 2. Write a report to warehouse mngr.
5 (B) Holding Time Time and Check/ Productio Productio n area <10 min, T=20- temperature measure n 250 C time and superviso temperature r Time : 1. Disposition of non-complying products every 10 minutes 2. Correct the cause to prevent recurrences T : Every 6 hours 3. Maintain record 4. Write a report to QA mngr.
Customer complaint
Microb.analysisof products
Packaging
6 (B) Holding Time Time and Check/ Productio Productio n area <10 min, T=20- temperature measure n 250 C time and superviso temperature r
Time : 1. Disposition of non-complying Microb. Analysis of products products Every 10 minutes 2. Correct the cause to prevent recurrences T : Every 6 hours 3. Maintain record 4. Write a report to QA mngr.
Receiving site Inspection of Receiving incoming eggs site Measure the Rh Storage Check the storage room / time warehous Check the e application of SSOP
Inspection of incoming eggs
Productio n area
Production supervisor
Packaging of bread
Productio n area
Production supervisor
T = 5-150 Temperature, Measure Wareho Warehous Every day C, label label of the temperature use e mngr. expired ingredients , check label date Every day T= C, label expired date 5-150 Temperature, Measure Wareho Warehous label of temperature use e mngr. cream , check label
Receiving site Inspection of Receiving incoming eggs site Measure the Rh Storage Check the storage room / time warehous Check the e application of SSOP
Inspection of incoming eggs
Productio n area
Production supervisor
Packaging of bread
Productio n area
Production supervisor
Frequency
T = 5-150 Temperature, Measure Wareho Warehous Every day C, label label of the temperature use e mngr. expired ingredients , check label date Every day T= C, label expired date 5-150 Temperature, Measure Wareho Warehous label of temperature use e mngr. cream , check label