Implementation of HACCP Management System in a Cake Manufacturing Company in Dhaka, Bangladesh: A Case Study

Md Fahad Jubayer,Md Sajjad Hossain,Md Al-Emran,Md Nasir Uddin,Vicente M G Mez L Pez

doi:10.1155/2022/5321333

Abstract

The study aims to provide technical information on the development and application of hazard analysis and critical control points (HACCP) in one of the popular cake manufacturing companies in Dhaka, Bangladesh. A generic HACCP plan in accordance with legal requirements was created after a detailed analysis of data collected from the company. Every step of the production process was examined for biological, chemical, and physical hazards. The prerequisite program was designed to address some hazards prior to production, thereby simplifying the HACCP plan. The critical control points were determined by answering the questions in the decision trees. Finally, the HACCP control chart was created to include critical limits, monitoring, and corrective actions as the components of several HACCP principles. One critical control point (CCP) and two operational prerequisite programs (oPRPs) were identified throughout the manufacturing process. This is the first HACCP study aimed at a cake manufacturing company, and it is expected that it would assist process engineers and quality control specialists in designing and implementing control measures.

Highlights

Cakes are popular sweet bakery products all over the world
According to an analysis of the hazard analysis and critical control points (HACCP) system applied in the company, there was no reduction in end-product quality during the manufacturing process, with notably strong application of prerequisites and entire commitment and sense of responsibility on the part of all employees
Numerous external factors can be a potential barrier in all stages of the HACCP implementation process, including (a) the illusion of control in the absence of adequate staff training; (b) company size as a potential factor due to a lack of resources, technical knowledge, and experience; (c) major industries that find it easier to implement the HACCP system than small businesses; (d) lack of HACCP program leadership; (e) lack of cooperation between industry and law enforcement authorities; (f ) insufficient equipment; (g) poorly designed equipment and an incorrect plan layout; (h) employee lackness of time to accomplish HACCP; (i) lack of equivalence of different types of HACCP programs [23]

Summary

Introduction

Cakes are popular sweet bakery products all over the world. E primary raw materials of cake include flour, sugar, egg, shortening [3], color, flavor, salt, and emulsifier, which are processed into finished goods via various processing steps such as mixing, baking, cooling, and packaging [4]. Foodborne illnesses are usually associated with this kind of processed products. Between 2004 and 2013, there were 142 cases of foodborne disease outbreaks and 2822 illnesses associated with bakery products in the United States [6]. Numerous food safety hazards associated with cake raw materials have been discovered, including aflatoxin B1 [7], mycotoxins [8], E. coli, Salmonella spp., Bacillus cereus, and several pathogenic microorganisms in flour [9]. Various types of hazards can be introduced during the cake manufacturing process through different processing steps such as food raw materials, processing equipment, processing environment, and food handlers

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Conclusion