Abstract
This study is aimed to develop the manufacturing process of the jelly mushroom drink using primary good manufacturing practice (GMP) for community enterprise, Phitsanulok, Thailand. The evaluation of the existing production process highlighted that the process had risks of cross-contamination, including from the plant layout, which still lacking in food safety management systems. Therefore, the improvement of process manufacturing and layout planning could be divided into three steps: (1) process analysis, (2) line production development, and (3) design plant layout to prevent and reduce crosscontamination causes. The cross-contamination incidence was reduced upon the improvement of the plant layout and processing as observed from the results of the amount of total plate count were reduced from 1.9 × 107 to <1 CFU/mL, where yeast and mold and 29 to 8.3 CFU/mL respectively. Meanwhile, the counts for Salmonella spp. and Staphylococcus aureus were below the detection level, whereas Clostridium perfringens, Bacillus cereus, and Listeria monocytogenes were not detected in all samples.
Highlights
A systematic layout plan allows the activity between the operator and the machine to go smoothly; increasing profitability to the company
The establishment of food production facilities should comply with the Primary good manufacturing practices (GMP) for the development of products to ensure quality, standard, and food safety; encountered by the manufacturer is that the jelly mushroom drink has short shelf life caused by microbial contamination in the processing line, which affected the time for product distribution and product quality
To effectively design the production flow, the process analysis has to be conducted via assessing the operation process chart (OPC) and flow process chart (FPC) of the jelly mushroom drink process
Summary
A systematic layout plan allows the activity between the operator and the machine to go smoothly; increasing profitability to the company. A systematic layout plan by applying an efficient production flow will result in the decreased idle time that can hold up the line. These requirements encompass the design and facilities of the establishment, hygienic processing, establishment of hygiene in the premises, personnel hygiene and health of employees, transportation, product information and documentation, and food safety training (Cocker, 2003). The establishment of food production facilities should comply with the Primary GMP for the development of products to ensure quality, standard, and food safety; encountered by the manufacturer is that the jelly mushroom drink has short shelf life caused by microbial contamination in the processing line, which affected the time for product distribution and product quality. Changchai et al / Food Research 4 (4) (2020) 1060 - 1065 safety guidelines by process analysis to prevent and reduce cross-contamination causes
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