Operational Prerequisite Programs Research Articles

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

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.

Application of Food Safety Management System (ISO 22000) In Processing of Wheat Flour Product

In this study, ISO 22000 food safety management system was applied and revised to produce wheat flour 72% extracted. This experiment was carried out in North Cairo Flour Mills and Bakeries Company, Al Kawther Flour Mill, El Salam City, Cairo, Egypt, all stages were followed up from receiving wheat to flour production and storage. A food safety team was created and that the infrastructure is suitable for the production process. A wheat flour product was described and a flow chart was constructed of the milling process. The hazard was analyzed and identification, cleaning stage and packing stage are critical control points (CCPs) while stage of receiving materials and stage of storing the product have been determined as operational prerequisite programs (OPRPs) and the effectiveness of implementing the HACCP plan is verified. The microbiological analysis of swabs from workers and surfaces was within the allowable limits and the microbiological analysis of wheat and flour was less than thirty (cfu/g). The chemical composition of wheat, the highest moisture content was during the conditions stage, regarding the chemical composition for wheat flour, results were similar in average values of readings in all stages. Heavy metal concentration of packaging material to use in packing wheat flour was within the allowable limits, Aflatoxins contents of wheat and flours were not detected in all stages, pesticide residues in flour was within the allowable limits.

Implementation of ISO 22000 System in Spaghetti Industry

The ISO 22000 Food Safety Management System has been applied to the spaghetti industry, in order to enhance food protection, protect customers, increase customer trust and improve cost efficiency. This experiment was carried out in North Cairo Flour Mills and Bakeries Company, Pasta Factory, Shubra El Khema, Cairo, Egypt, all stages were followed up from the receiving wheat flour extract 72% to spaghetti production and storage. Beginning with the appointment of the food safety team and that the infrastructure is suitable for the production process, the spaghetti product was described, a flow chart was constructed of the manufacturing process, the hazard was analyzed and identification, the sieving stage, drying stage and packaging stage were identified as critical control points (CCPs), while stage of receiving materials and stage of storing the product have been determined as operational prerequisite programs (OPRPs) and the effectiveness of implementing the HACCP plan is verified. The microbiological analysis of swabs from workers and surfaces was within the allowable limits. The results showed that no significant differences between the chemical composition of spaghetti. The heavy metal concentration of packaging material to use in packing spaghetti was within the allowable limits.

Food Safety System (HACCP) as Quality Checkpoints in a Spin-Off Small-Scale Yogurt Processing Plant

The present study describes the implementation of a food safety system in the dairy pilot plant “Gourmeticus Academicum,” a spin-off within the University of Agricultural Sciences and Veterinary Medicine of Cluj Napoca, Romania. In order to improve Hazard Analysis of Critical Control Points (HACCP) the preliminary programs were integrated into the quality management system (QMS) by monitoring the biological hazards. The process provides future specialists with good practice hands-on and educational tools. This study focused on hazard analysis, the determination and establishment of prerequisite programs, and the role of critical control points (CCPs) based on HACCP and the challenges found during the process as a critical thinking model on education programs. The determination of the CCPs in the processing of yogurt was made by applying the decision tree method. Besides, biological hazards are included as a by-control of the system’s implementation performance. For the successful implementation of HACCP principles, prerequisite programs (PRPs) and operational prerequisite programs (OPRPs) were initially implemented. This process could be challenging but feasible to be reached in small-scale food industries with remarkable results as educational tools.

Controlling of Microbial Hazards for Potato Chips manufacturing through Food Safety Management System (ISO 22000)

Food safety is a fundamental public health concern, and achieving a safe supply poses major challenges for organization involved in the food chain, so numbers of foodborne hazards must be properly analyzed, assessed and managed to meet growing and increasingly complex sets of global food chain. Proper implementation of food hygiene principle across the food chain in conjunction with hazards analysis and critical control points system will ensure food safety. In this study, Microbiological hazards were controlled for two fried potato chips production lines, processing & packaging for each line starting from raw materials receiving, storage…etc, where microbiolgical tests were carried out at all stages of product production on raw materials received, water used in the manufacturing process, microbiological swabs were taken from the equipment and surfaces of the processing and packaging lines as well as the hands of the workers, in short the stages of potato chips production are as follows: Potatoes receiving & storage ==> Washing ==> Peeling ==> Manual sorting ==> slicing ==> washing and remove starch ==> Frying ==> Optical & Manual sorting ==> Seasoning ==> Packaging and print coding ==> Palletizing. Based on actual conditions in the plant a specific Hazard analysis and critical control point (HACCP) model has been developed to ensure safe product, reduce and support the traditional inspection and quality procedure of fried potato chips product through food safety management system ( FSMS-ISO 22000), the prerequisite programs (PRPs), operational prerequisite programs (OPRPs), critical control point (CCP), critical limits, preventive, monitoring procedures and corrective actions have been designed in this HACCP plan.

HACCP Plan and Adoption of HACCP Metasystem in the Tea Industries of Bangladesh

HACCP (Hazard Analysis and Critical Control Points) metasystem is a concept not much familiar to the tea industries of Bangladesh. This study was conducted to investigate the issue of food safety through HACCP metasystem and conduct a hazard analysis to make a comprehensive model of HACCP plan for the tea industries of Bangladesh. Both qualitative and quantitative data analysis was used to determine the CCPs (Critical Control Points) or OPRPs (Operational Pre-Requisite Programs) and design a HACCP plan through risk assessment and seven logical approaches. Two OPRPs and CCPs were determined. The derived CCPs were the biological hazard in the cultivation stage and the physical hazard in the processing step namely CTC (Crush, Tear and Curl) and Googy shifter step. The biological hazard in the cultivation stage can be controlled by proper application of GAP (Good Agricultural Practice) while the physical hazard can be controlled in the processing step by proper maintenance of the magnetic arrestor. Considering the benefits and constraints, standard processing procedures and guarantees of food safety of tea as well as to stay in the competitive global market the tea industries should adopt HACCP metasystem.

CONTROLLING OF POTENTIAL HAZARD IN POTATO CHIPS PROCESSING THROUGH FOOD SAFETY MANAGEMENT SYSTEM FSMS (ISO 22000)

The purpose of this study is to design Hazard Analysis and Critical Control Point (HACCP) plan for potato chips production through food safety management system F.S.M.S ISO 22000 based on actual conditions in the plant. A specific model has been developed to boost the safety and quality of potato chips product in this plant. The prerequisite programs (PRPs), operational prerequisite programs (OPRPs), hazards, critical control point (CCP), preventive measure, critical limits, monitoring procedure and corrective actions have been designed in this HACCP plan. Microbiological analysis for incoming flavors were within the acceptable limits and thus the incoming shipments were accepted and no acceptance from the supplier in case of out of the acceptable limits. The results showed that microbiological examination of raw potatoes before and after frying that frying process could significantly reduce all microorganisms in raw potatoes to the acceptable level on two processing lines. A program of cleaning and disinfection of production lines and a personal hygiene program for the workers and ensuring the effectiveness of them as well as the quality of the water entering the manufacturing process. Chemical, microbiological, physical and sensory tests were conducted to ensure the safety and quality of the finished product.

CONTROLLING OF POTENTIAL HAZARD IN POTATO CHIPS PROCESSING THROUGH FOOD SAFETY MANAGEMENT SYSTEM FSMS (ISO 22000)

The purpose of this study is to design Hazard Analysis and Critical Control Point (HACCP) plan for potato chips production through food safety management system F.S.M.S ISO 22000 based on actual conditions in the plant. A specific model has been developed to boost the safety and quality of potato chips product in this plant. The prerequisite programs (PRPs), operational prerequisite programs (OPRPs), hazards, critical control point (CCP), preventive measure, critical limits, monitoring procedure and corrective actions have been designed in this HACCP plan. Microbiological analysis for incoming flavors were within the acceptable limits and thus the incoming shipments were accepted and no acceptance from the supplier in case of out of the acceptable limits. The results showed that microbiological examination of raw potatoes before and after frying that frying process could significantly reduce all microorganisms in raw potatoes to the acceptable level on two processing lines. A program of cleaning and disinfection of production lines and a personal hygiene program for the workers and ensuring the effectiveness of them as well as the quality of the water entering the manufacturing process. Chemical, microbiological, physical and sensory tests were conducted to ensure the safety and quality of the finished product.

A Model HACCP Plan for Fish Seasoning Powder Production

Many kinds of seasoning powder available in market contain high amount of monosodium glutamate (MSG) in Myanmar. So, natural seasoning powder without MSG from fish and vegetables seasoning powder was considered for safe and healthy product as substitute of MSG. The main aim of this research is to design Hazard Analysis and Critical Control Point (HACCP) plan for fish based seasoning powder production. Local indigenous raw materials such as Ngar-Gyin (Mrigal fish), cabbage, carrot, cauliflower, chinese cabbage, garlic and ginger were used in the formulation of fish based seasoning powder. The prerequisite programs (PRPs), operational prerequisite programs (OPRPs), hazards, critical control point, preventive measure, critical limits, monitoring procedure and corrective actions have been designed in this HACCP plan. A sample generic HACCP plan was recommended. Three Critical Control Points (CCPs) in the processing; cold storage of raw fish; pressure cooking and packaging were identified. A HACCP plan was completed with perquisite programs dealing with the identified hazards.

Microbiological Control of UHT Sterilized Milk and Milk Products and Effects on Consumers' Health in Western Algeria

The present study focused on the analysis of microbiological quality of various milk samples such as ultra-high temperature sterilized milk (UHT), melted cheese and yoghurt, obtained from dairy product factories in western Algeria. Hazards identification and development of a quality management standard for these subsidiaries evidenced that the sanitary quality was satisfactory. The result revealed detection of faecal origin contamination ‘total and fecal coliforms’ in both the yoghurt product and sample of melted cheese where the average content was(1.29±6.72-0.14±0.56 x 103cfu/g) and (0.14±0.6-0.022±0.275 x 103cfu/g) respectively. It is indicative that all samples were free from Staphylococcus aureus and Salmonella sp. The study demonstrated that prerequisite programs (PRP) will prevent the occurrence of microbiological hazards origin, which confirms the fact that hygiene measures are the best safety assurance. The hazard analysis of the production process of yoghurt and cheese allowed us to find out their causes, adoption of preventive measures for certain sensitive stages where hazards can be eliminated or reduced at acceptable levels, the determination of critical control points (CCP)and operational prerequisite programs ‘PRPo’, implementing critical limits, and monitoring plans. DOI: http://dx.doi.org/10.3329/mh.v3i1.19777 Microbes and Health, June 2014. 3(1): 21-24

Physico-chemical quality assessment of ultra high temperature sterilized milk and milk products in Western Algeria

The present study focused on the physico-chemical and bacteriological quality assessment of samples including ultra-high-temperature (UHT) sterilized milk, melted cheese and yoghurt, collected from dairy product factories in western Algeria. Hazards identification and development of a quality man-agement standard for these subsidiaries were established. The physico-chemical and bacteriological quality of products analyzed was satisfactory, with the exception of 20% of the samples of fruity yoghurts where the titrat-able acidity was relatively high 1.337 ± 0.143%. Prerequisite programs (PRP) established will prevent the occurrence of hazards microbiological origin, which confirms the fact that hygiene measures are the best safety assurance. The hazard analysis of the production process of yoghurt and cheese allowed us to determine their causes, preventive measures for certain sensitive stages where hazards can be eliminated or reduced to acceptable levels, the de-termination of critical points for mastery (CCP) and operational prerequisite programs (PRPo), establishing critical limits, and monitoring plans. Awareness actions and information on potential risks are essential for consumers.

A QUANTITATIVE RISK ASSESSMENT APPROACH IN AN INTEGRATED COLD CHAIN SYSTEM ENSURING OPTIMAL SAFETY AND RELIABILITY FOR INDIAN AGRARIAN MARKET

India has an agrarian economy. More than 52% of it's land is engaged in cultivation and with varying demography across the length and breadth of the nation, India has one of the most diverse vegetative portfolio. Each genre of produce has limits to the timetemperature abuse it can withstand beyond which deterioration starts from within which may not be apparent. We present a logistic model which ensures easy quality management of food produce emphasizing on optimization of produce quality and minimization of wastage and spoilage. The model deals with specific products and their relationship with standard tolerance levels to temperature abuse patterns along with measures to minimize them. We use the basic principles of Hazard Analysis Critical Control Points (HACCP) in sync with operational pre-requisite programs to devise a robust system helping us achieve the desired level of optimization. Based on the Hub and Spoke model for freight transfer, this model focuses of two fundamental parameters, distance between the point of cultivation to the point of sale and time taken to traverse that distance maintaining the required time-temperature combinations. The algorithm emphasizes on acquiring data that can be utilized to predict a problem and assessment of risk before it occurs. This intervention can be made to mitigate product issues resulting cost impacts using the hype cycle for food supply chain. The system is intended to monitor produce temperature history, chain of custody and helping to ensure that a food is safe and effective throughout the supply chain when reaching its intended consumer.

An Assessment on Aflatoxin Control in Pistachio‐Processing Units from Raw Material Reception to Packaging Based on ISO22000:2005 Model

AbstractBecause of the importance and usage of pistachios, it is necessary to improve their agricultural situation, particularly by establishing good processing equipment and packaging units near pistachio farms. It is possible to supply a high‐quality product in large quantities for foreign and domestic markets. In this research, International Organization for Standardization 22000:2005 requirements were implemented in a pistachio‐processing unit. Aflatoxin B1 content was measured by high‐performance liquid chromatography before and after washing, immersing pool, wet sorting, drying, temporary storage and dry sorting. After analysis of measured data, it was found that the most reducing stage in aflatoxin content was wet sorting. Washing stage had no significant effect on aflatoxin B1 reduction. It is concluded that operational prerequisite program and critical control point have no differences important to hazard control, but they are different from a type of control measure aspect.Practical ApplicationIn this study, the authors employed food safety management system based on International Organization for Standardization (ISO) 22000:2005 model to prepare safe pistachios with less aflatoxin content. All process units (pistachio reception, de‐hulling, washing, immersing pool, dehumidifier, goo separator, wet sorting, drying, temporary storage, dry sorting, packaging) evaluated upon ISO22000:2005 requirements. Then the stages that had more significant effect on aflatoxin B1 content identified. The quantification of aflatoxin B1 in accordance with standard methods was also explained in the paper. The authors also investigated operational prerequisite programs and critical control points in hazard control.

The Design of HACCP Plan for Potato Chips Plant in Bangladesh

The purpose of this study is to design Hazard Analysis and Critical Control Point (HACCP) plan for potato chips production based on actual conditions in the plant. A specific model has been developed to boost the safety and quality of potato chips product in this plant. The spread of some diseases by unsafe products due to pathogen reported makes it important to pay attention to the potential contamination in potato chips production. The prerequisite programs (PRPs), operational prerequisite programs (OPRPs), hazards, critical control point, preventive measure, critical limits, monitoring procedure and corrective actions have been designed in this HACCP plan. The production process of the product was also analyzed scrupulously for this HACCP plan.DOI: http://dx.doi.org/10.3329/jesnr.v5i2.14839 J. Environ. Sci. & Natural Resources, 5(2): 329-338 2012

Validating Food Systems to Ensure Safe Products

When developing a food safety management system (FSMS), processors need to clearly define potential hazards and develop and implement preventive measures. In this column, Stier looks at what processors can do to properly validate the steps in the process or activities that are deemed essential for food safety. The steps in the process are critical control points (CCPs), and the activities are those prerequisite programs deemed essential for ensuring safety—the operational prerequisite programs (oPRPs). Three simple rules for designing an FSMS are identified: 1) validate when developing the program to ensure that the CCPs and oPRPs are effective; 2) monitor the system daily to provide a record that the work is being done and done properly; and 3) verify after the fact using tools that provide evidence that the work was done properly. To ensure success management must support all of these activities.