Food Safety Management System

Food Safety Management System - Safwan’s Curry Paradise

Module: Food Safety Engineering and Management Tutor: Dr Gary Weeks Student: Pedro Pereira Candiani Student number: V8213544 Date of submission: 20/05/2019

Contents 1.

Scope ..................................................................................................................................... 3

2.

Current scenario ................................................................................................................... 3

3.

Prerequisites ......................................................................................................................... 5 3.1.

Allergen control ............................................................................................................ 5

3.2.

Management of purchased materials .......................................................................... 6

3.3.

Storage .......................................................................................................................... 7

3.4.

Foreign body control .................................................................................................... 8

3.5.

Traceability and product recall .................................................................................. 10

3.6.

Training ....................................................................................................................... 12

3.7.

Construction and design including internal structure ............................................... 13

3.8.

Utilities (Air/Water).................................................................................................... 13

3.9.

Equipment................................................................................................................... 14

3.10.

Waste management ............................................................................................... 15

3.11.

Pest control ............................................................................................................. 16

3.12.

Cleaning procedures ............................................................................................... 17

3.13.

Temperature control .............................................................................................. 18

3.14.

Transport................................................................................................................. 18

3.15.

Non-conformance procedures ............................................................................... 19

3.16.

Personal Hygiene .................................................................................................... 19

4.

Management Responsibility & Selection of the HACCP Team.......................................... 20

5.

Description of the Product ................................................................................................. 21

6.

Process Flow Diagram and On-site Confirmation .............................................................. 22

7.

Hazard Analysis ................................................................................................................... 25

8.

Validation and Verification of the HACCP Plan ................................................................. 32

9.

Documentation and Record Keeping ................................................................................. 33

10.

Recommendations .......................................................................................................... 33

11.

References ...................................................................................................................... 33

12.

Appendices...................................................................................................................... 41

12.1.

Appendix 1: decision tree ....................................................................................... 41

1.

Scope

This report will analyse the current status of the Safwan’s Curry Paradise, a manufacturer of ready-to-eat foods in the United Kingdom, and will propose changes in order to improve the food safety of this business.

The factory has a 10 years history and supplies to the public sector in the north of England, where currently is the number one supplier of Halal and Ethnic food. Among the products manufactured in this facility is Butter Chicken, Chicken Balti and Tikka, Madras Fish Curry, Prawns in a butter-tomato sauce, boiled rice, pilau rice, vegetable pilau, Bombay potatoes, Tadka Dal, Coconut Dal and Tomato and onion cachumbar.

2.

Current scenario

The factory counts with 48 employees divided in several functions, as presented below: •

1 Managing Director

•

1 Finance Manager

•

1 Sales manager

•

1 Operations manager

•

1 Transport manager

•

2 Supervisor, one for each shift

•

24 production staff

•

4 hygienists

•

8 drivers

•

2 sales staff

•

2 telesales operators

•

1 handyman

The current layout is shown in the figure 1 below. A few hazards can be spotted in this layout, in example, the general store is outside the main building, which can facilitate pests or physical contamination during the transport between the two buildings. In addition, rubbish and waste are disposed near the line of production, more specifically, the raw material storage, which can attract pests and, also, contaminate the raw material with bacteria that could have grown in the rubbish or waste. Finally, the finished product storage is open, which makes harder to control the temperature and the entrance of pests, bacteria or other material that can offer a hazard to the safety of the food.

RUBBISH WASTE RAW MAT. STORE

GENERAL STORE

INGREDI ENTS

PRIMARY PROCESSING AREA

RAW MATERIALS HANDLING CONTAINER WASH

COOKING AREA HAND & BOOT WASH

SHOWERS & TOILETS

SHOWERS & TOILETS

PACKAGING STORE

PACKAGING AREA (PRESSURISED)

FINAL PROD. STORE

SECONDARY PROCESSING HIGH CARE AREA (PRESSURISED)

LABORATORY

LOADING

CHEMICAL STORE

WC

Figure 1: current layout of the factory.

In addition, the background information provided for the development of this report states that the heating and cooling processes as well as the food prepared in advance and maintenance are inadequately controlled, there is no physical contamination and temperature control and the factory has poor standards regarding the stock control and hygiene.

3.

Prerequisites

Before a Hazard Analysis and Critical Control Point (HACCP) system is applied to the factory, there are some prerequisites, or good manufacturing practices (GMP) that should be put in place to allow the HACCP to be focused on the significant hazards. In other words, GMP are the minimum standards that a company should follow to provide safe food for the consumers, as presented by Gall, K. (2008). The sections below will discuss these minimum requirements mentioned above.

3.1. Allergen control

According to Ward, R. et al (2010), allergens are considered a food safety hazard, which can cause an immune response that leads into adverse health effects, as stated

by Huby, R. D. J., Dearman, R. J. and Kimber, I. (2000), and possibly death, as explained

by Crevel, R. and Cochrane, S. (2013). Therefore, due to the severe costs of the contact of a person with an allergen, is essential to manage safely these ingredients and follow all guidelines and good practices in order to avoid people to ingest a food with a substance that they are allergic. It is, as stated by Crevel, R. and Cochrane, S. (2013), necessary to always pay attention to the allergens during the whole production to allow that a safe choice is done by the consumer when buying a product.

The Food Standards Agency (FSA) (2006) and FoodDrinkEurope (FDE) (2013) divided the allergen management in a few key areas, like people, raw materials and supply chain, equipment and factory design, processes, cleaning, new product development and packaging. For a successful management of the allergens, all these points should be covered.

Therefore, the management of Safwan’s Curry Paradise should implement all the following measures that are presented in the further sections.

3.2. Management of purchased materials

Regarding the purchased materials, the suppliers must provide information about the composition of each ingredient, shelf life, storage conditions and the FDE (2013) recommends that information about allergen content and food safety measures of the ingredients bought is requested from them and regularly reviewed. All the suppliers must have an allergen control police and good manufacturing practices active and provide documentation that ensure that measures have been taken in order to prevent any cross-contamination with an allergen and physical, microbiological or chemical contamination of the material whilst in the supplier possession. All material received must be checked upon arrival and if any of the ingredients is or contain an allergen, it should be identified and kept sealed if possible. In addition, it is better if the allergens could be stored in a different place from the other ingredients, which will be covered in further sections.

3.3. Storage

According to the Codex Alimentarius (2017), dry foods, such as spices, should be stored in a dry and cool place in order to keep the water activity below 0.65. Powitz, R. W. (2005), suggests the use of air conditioning or dehumidification to maintain the humidity level of the storage at or below 15%. The products also need to be kept away from the wall, to prevent any contact with a possible condensation, and off the floor, as explained in the Codex Alimentarius (2017). In addition, Powitz, R. W. (2005) highlights that is best to avoid direct sunlight, since it can lead to oxidation and loss of nutritional quality and value.

The Food Safety and Hygiene (England) Regulations (2013) states that the storage temperature of chilled food needs to be maintained under 8째C, however, according to the Codex Alimentarius (2017), it is best to target 5째C. For freezing temperature, the interval is between -18째C and -21째C. These conditions mentioned above are required to ensure the safety of the ingredients by slowing both the growth of bacteria, moulds and other microorganisms that could be harmful to someone and spoilage and deterioration reactions, as explained by James, S. J. and James, C. (2013). In addition, low temperature helps in controlling pests, as explained by Jian, F. (2019), which will be addressed later. Also, as mentioned above, the allergens should be stored separately from the other ingredients and correctly labelled, in order to prevent cross-contamination. Additionally, proper stock rotation can help to prevent spoilage and deterioration, the factory should use the concept of first in, first out (FIFO) when selecting the ingredients for production. That

requires an up to date record of the ingredients that are coming in and out the storage room.

Therefore, the storage conditions for the ingredients used by the Safwan’s Curry Paradise to produce the Butter Chicken are presented below in the table 1. The finished products made by this company must be refrigerated below 5°C. Ingredient Chicken breasts Black pepper Coriander Garam masala Cumin Paprika Salt Garlic Lemon juice Lime Juice Root ginger Double Cream Unsalted butter Yoghurt

Allergen

Condition

No

Frozen between -18°C and -21°C

No No No No No No No No No No Yes, milk Yes, milk Yes, milk

Dry; Room temperature Dry; Room temperature Dry; Room temperature Dry; Room temperature Dry; Room temperature Dry; Room temperature Refrigerated below 5°C Refrigerated below 5°C Refrigerated below 5°C Refrigerated below 5°C Refrigerated below 5°C Refrigerated below 5°C Refrigerated below 5°C Table 1: storage conditions.

The chemicals used for cleaning should be stored in a dry and with enough ventilation area in a separate place to avoid cross-contamination with food or surfaces where food is handled, as presented by FAO (1998).

3.4. Foreign body control

‘’Foreign body is a technical term which refers to any extraneous matter, whether of a physical, chemical or biological nature, found in food’’, as explained by Goodwin, D. (2014). It can be a piece of glass, stones, metal, wood, fruit pit or bones and

can lead to injuries such as cuts, choking, infection and broken teeth, as presented by Stier, R. F. (2014). Therefore is a food safety matter that has to be addressed with attention. Safwan’s Curry Paradise has to take all actions possible to prevent contamination with a foreign body in order to, not only, comply with legislations, but also improve the safety of the food and protect the brand, since if a consumer find a contaminated product it can lead to bad image, as pointed by Goodwin, D. (2014).

Stier, R. F. (2014) describes a few actions that can help to prevent the contamination with foreign bodies, which will be explained below. As part of the safety measures mentioned in the sections above, the company should require that the suppliers submit their products to a detection stage immediately before packaging, ensuring that the ingredients bought are not contaminated. Preventing pests to have access to the factory is also a possible measure and how to do it will be addressed later.

In addition, to avoid contamination with glass or brittle plastic any items made of these material should be carried into where the food is produced. Windows must be shatterproof or coated with plastic, light fixtures must be protected and the company must keep records of the presence of all glass and brittle plastic in storage or production line. If there is a glass or brittle breakage the company has to apply the procedure presented in the figure 2, as pointed by Safe and Local Supplier Approval (SALSA) (2015).

Lastly, proper cleaning, building management, maintenance and personal hygiene are factors that will reduce the likelihood of a contamination, these will be addressed in further sections.

Figure 2: Glass and brittle breakage procedure.

3.5. Traceability and product recall

Traceability is defined by the FAO (2017) as “the ability to discern, identify and follow the movement of a food or substance intended to be or expected to be incorporated into a food, through all stages of production, processing and distribution” and the FAO (2017) defines product recall as “the action to remove food from the market at any stage of the food chain, including that possessed by consumers. For the purposes of these Regulations, recall refers to food safety and food quality-based recalls”.

According to Fisher, W. (2015), traceability is key to reacting to an emergency since it facilitates planning by giving a greater visibility of the supply chain, the parts involved can act with more agility in case of a recall, which is easier due to the information recorded of the products. In addition, traceability provides information to identify where the problem occurred, facilitating it to be fixed.

Therefore, to achieve the expected results the Safwan’s Curry Paradise should keep record of all suppliers of the ingredients and all business that they supply the ready-to-eat food. The information required to be recorded is the name, address, type and quantity of product bought or sold, dates of transaction and delivery and batch number, as presented by the FSA (2018).

In case of a problem with one of the products it is necessary to do a recall, which will be a lot easier if all products are traceable. According to the FAO (1998) it is required to have a written recall procedure containing the information presented in the table 2 below.

Recall procedure: required information Name of responsible Method for identification, localization and control of the recalled food Investigation requirement for other products that may have been affected Monitoring procedure of the effectiveness of the recall Quantity of food produced Name, size, code, batch number of the food Distribution location Reason for recall Table 2: information for recall.

3.6. Training

Regarding the allergen management, all staff should be trained to avoid the risk of cross-contamination, the training must cover the points presented below, as presented by FSA (2006): •

Recognising which ingredients are the allergens of concern and why.

•

Identifying potential allergen cross-contamination situations.

•

Hand washing.

•

Clothing requirements including laundering.

•

Re-work procedures.

•

Waste management procedures.

•

Cleaning procedures.

•

Dedicated equipment if available.

•

People movement around the site, for example, people changing production line or site, trips to the canteen and visitors.

•

Equipment movement around the site, for example, maintenance tools, food trays, etc.

The FSA offers a free online course and there are several companies in the United Kingdom that offers a more specific training, for example a Campden BRI provides a training on the client’s premises.

In addition, all the staff should receive a training about personal hygiene that covers the points highlighted in the personal hygiene section.

3.7. Construction and design including internal structure

In order to facilitate cleaning procedures, maintenance and avoid pests it is necessary to pay attention to equipment location and design. In addition, the structure of the factory needs to be made of durable materials and not difficult to keep in good conditions and clean, as presented by FAO (1998). Moreover, the FAO (1998) describe with more detail the specifications for the structure, which is shown below in the table 3. The exterior of the factory should not allow the entrance of pests, which will be detailed in a further section. Finally, maintenance is essential to avoid points where pests or contaminants can get access to the factory, holes in the wall or ceiling for example.

Structure Wall’s surface Walls and partitions Floors Ceilings and overhead fixtures Windows Doors Working surfaces

Characteristics Water resistant; non-toxic Smooth surface up to appropriate height Easy to clean; proper drainage Designed to avoid dirt and condensation accumulation and shedding of particles Fitted with screens to avoid pests; Designed to avoid dirt and condensation accumulation; easy to clean Smooth and non-absorbent surface; easy to clean Non-toxic; Non-absorbent; Inert to detergents and disinfectants Table 3: structure characteristics.

3.8. Utilities (Air/Water)

The water supplied to the factory must be identified by potable, which is safe to drink without any potential hazard to the health of a person, and non-potable, which can be used to cleaning procedures, fire control, and refrigeration. The FSA (2013)

demands that each type of water must circulate in a separate system and no contact between them to prevent any risks of contamination.

The air quality is an important aspect of the food safety since it is possible to have contamination with water, dust, bacteria, yeast and mould, as presented by Sparks, S. (2014), brought from outside or a party of the factory that has not been cleaned.

According to FAO (1998), ventilations systems can help to minimize air-borne contamination, control odours, temperature and humidity. However, the flow needs attention in order to avoid the contamination of an area where food is stored or produced.

3.9. Equipment

Equipment maintenance is an important action regarding the food safety since if not in a good condition it presents a potential source of microbiological and physical contamination, as explained by Wright, J. (2018). Metal pieces caused from wear, flaking paint, lubricant and rust are examples of physical and chemical contamination resulted from a poor maintenance, according to the same author. According to Martin, E. (2016), the best maintenance practice is the predictive maintenance, which ‘’identifies, measures, and earmarks factory equipment requiring maintenance before a failure occurs’’ as explained by Martin, E. (2016). The scheduling in this approach is based on the health of the machine allowing a potential problem to be solved before it occurs.

The equipment is monitored in real time by devices using Bluetooth, for example, and this can improve the efficiency of the production line, reduce costs and use of personal, besides improving the food safety, as presented by Wright, J. (2018). According to the FAO (1998), the maintenance programme should present the list of equipment, the

method and if any parts will be replaced and the frequency. The maintenance can also be scheduled together with cleaning, then it is ensured that no parts or chemicals from the maintenance remain in the equipment. At last, Wright, J. (2018) recommends that an independent service is hired, which can ‘’shorten the learning curve, delivering insights and best practices from other industries as well as other food producers’’, as explained by Wright, J. (2018).

3.10. Waste management

According to the Food and Agriculture Organization of the United Nations (FAO) (1998), containers used to dispose the waste should be leak-proof and well identified.

In addition, they need to be made of suitable material, in order to avoid that rodents, birds or insects are able to reach the disposed material inside the container. The material must be easy to clean and disinfect, as presented by Regulation (EC) No 852/2004 on the hygiene of food stuffs. The waste and rubbish generated during the production process has to be taken to a different place from where the food is being prepared as soon as possible as required by the Regulation (EC) No 852/2004 on the hygiene of food stuffs.

Moreover, as presented by FAO (1998) the waste must be removed from the storage within a regular schedule and cleaning procedures must be put in place to avoid the attraction of any kind of pests. These measures will avoid cross-contamination promoted by pests that could have contact with waste and the raw ingredients.

3.11. Pest control

According to Fredericks, J. and Mannes, C. (2016), pests could bring bacteria and viruses into the food and, also, contaminate it with feces and urine, which results is a hazard for the human health. Therefore, pest control should be considered a key concern for food safety. In addition, pests like rodents and birds can damage the structure of the facility, by gnawing wires, for example, as presented by Fredericks, J. and Mannes, C. (2016).

Considering the dry ingredients used by the Safwan’s Curry Paradise, Fredericks, J. and Mannes, C. (2016) points that rodents, birds and beetles are the most likely pests to try to access the food source. In order to prevent these pests from getting access into the facilities, holes and drains should be sealed and windows, doors and ventilations should be wired with mesh screen, as explained by the FAO (1998). In addition, the ingredients must be checked for pests when received and, if it does not contain any pests, stored off the floor, away from the walls and packed in pest-proof containers.

Another measure to prevent infestation from insects is the use of low temperatures (below 18°C), as already mentioned above. This measure decreases the insects’ movement, food consumption, growth and multiplication, as explained by Jian, F. (2019).

To ensure that no pests will infest the factory Fredericks, J. and Mannes, C. (2016) suggests that an integrated pest management program is put in place and that is done by a contracted company. Rentokil is one example that provides this service and they divide the process in four parts, presented in the figure 3 below.

Figure 3: pest control approach.

Finally, two other measures can be put in place to avoid pests in the factory.

Proper waste disposal, as mentioned in the section above, and cleaning procedures, which will be addressed in the section below.

3.12. Cleaning procedures

As pointed by Diversey Care (2015), cleaning is a critical stage to ensure the food safety when producing food. According to them, this action not only prevent microbial contamination but also can improve the efficiency and reduce losses by spoilage.

Cleaning and disinfection are procedures that contribute to pest control and allergen management. The first because it removes any material that could attract insects, birds or rodents and the second because it prevents cross-contamination by cleaning in between production if an equipment is used to produce food with and without an ingredient that is an allergen.

The FSA (2018) highlights the importance of a cleaning schedule where definitions of what needs to be cleaned and disinfected, the frequency and the method is described. In addition, it is important to inform which products and its quantities should be used to clean and disinfect different places and how they should be stored after using. Moreover, the name of the responsible for the cleaning, date, products and proportion used and procedure must also be recorded, as presented by FAO (1998).

3.13. Temperature control

Since the food produced by this factory requires refrigeration to prevent spoilage and microbial growth, it is recommended that the secondary processing and packaging area are refrigerated under the conditions specified in the storage section. In conformance with The Food Safety and Hygiene (England) Regulations 2013, the loading area does not need to be refrigerated since the product is being loaded.

3.14. Transport

The transportation between the factory and the consumers can be a challenge not only for the safety of the food but also for the quality, as presented by Hernandez, J. A. (2009). If the food is held in the wrong temperature it can spoil or lose quality and if in contact with other material it can be contaminated with dirt, for example.

The Safwan’s Curry Paradise factory will distribute food that needs to be chilled.

Therefore, the transport needs to have a refrigeration system to maintain the food at a maximum of 5°C, as mentioned in the storage section. In addition, it is best if the vehicle is only used to transport food and the products are transported in a packaging or container, to prevent external contamination, as presented by FSA (2018).

3.15. Non-conformance procedures

Litshie, M. (2014) defines a non-conformance as ‘’ a non-fulfilment of a specified requirement, a failure to conform or comply with accepted standards or requirements of a quality or other system’’ and is a complex effort, according to Koeris, M. (2017). By keeping record of the non-conformances it is possible to apply a continuous improvement, because the company will be constantly evaluating the processes and this will allow the identification of the causes of the non-conformances, as explained by Koeris, M. (2017). Both Listhie, M. (2014) and Koeris, M. (2017) highlights the importance of properly keeping record of a non-conformance, analysing it and applying effective corrective actions to improve the process and, therefore, the safety of the food.

Therefore, the staff of the Safwan’s Curry Paradise should be instructed to always document when a non-conformance happens, it will help to improve the process and protect the brand. As highlighted by Koeris, M. (2017) it is necessary to promote a proactive safety culture with engagement of all members of the company, from management to manufacturing line.

3.16. Personal Hygiene

Personal hygiene can help to prevent food contamination with bacteria, viruses and dirt, brought from outside the production line, and allergens from contact outside the factory or with an ingredient that contains an allergen.

The staff of Safwan’s Curry Paradise should be trained to properly wash hands and wear clean work clothes when inside the area where food is being prepared. In

addition, they must maintain their hair tied back and, also, wear a hat or hair net, as required by the FSA (2018). Moreover, jewellery and watches should be removed, with exception of wedding band, and the staff must avoid touching face and hair, eating, smoking, spit or sneeze while preparing or handling food, as explained by the FSA (2018).

Washing hands, according to the FSA (2018), is essential to ensure food safety and must always be done before handling and preparing food and after touching raw food, cleaning, dealing with food waste or rubbish, blowing the nose and touching phones, light switches, door handles and cash registers, as required by the FSA (2018).

Additionally, according to the FSA (2018), any member of staff that is ill with a disease that presents a risk to the food safety or have diarrhoea or infected wounds, skin infections or sores must not be allowed to be where food is handled. If one of the employees has a cut it needs to be covered with a coloured waterproof dressing before handling food.

4.

Management Responsibility & Selection of the HACCP Team

When implementing the HACCP plan it is essential to have full support from the management to the lowest levelled employee, with the management being critical, as presented by FAO (1998). This fact is also explained by Andrews, K. R. (2006) when he points that the leadership commitment is highly important to the success of a new plan.

According to the US Food and Drug Administration (FDA) (1997), this commitment makes the employees to realize that producing safe food has a high importance.

According to the FDA (1997) the team should have complementary expertise in engineering, manufacturing, sanitation, quality assurance and microbiology. The FAO

(1998) complements pointing that since each process has its own characteristics it is important to include people that are directly involved with the production, because they will have a better knowledge regarding specific variations and limitations of the processes. Both FAO (1998) and FDA (1997) suggests that is interesting to bring knowledge from outside. However, the development of the HACCP plan should not be done only by an outside source. In addition, the United States department of agriculture (USDA) (1999), states that one of the members of the team must have been trained in HACCP, but it is not a requirement that this person is an employee.

Considering the employees at Safwan’s Curry Paradise, the team should involve the managing director as the project sponsor, the operation and transport managers, one of the supervisors and one of the hygienists. Since there are no personnel with microbiology and quality assurance expertise and HACCP training, these three spots must be filled by hiring from external sources.

5.

Description of the Product

The product chosen is the Butter Chicken, a dish made with chicken Balti and Pilau rice. The information regarding this product are presented below in table 4.

Common name: How is the product to be used: Packaging type: Shelf-life: Selling places: Label instructions: Special distribution control:

Butter Chicken Cook from chilled Bulk package with sleeve and film lid 5 days, stored below 5°C Supplied to the public sector, convenience stores Cooking instruction, storage conditions, halal label, safe food handling label Refrigerated vehicle with temperature below 5°C Table 4: product information.

The list of ingredients used for the preparation of the Butter Chicken is presented below in table 5. According to Odumeru, J. (2002), Campylobacter, Listeria, Salmonella, verotoxigenic E. coli (VTEC), Staphylococcus aureus, and Bacillus cereus are some of the microorganisms that presents a potential hazard related to milk and derivates.

Regarding the chicken, Salmonella and Campylobacter are concerns, as presented by Rouger, A., Tresse, O. and Zagorec, M. (2017). Banerjee, M. and Sarkar, P. K. (2003) state that Bacillus cereus and members of Enterobacteriaceae are present in many spices. The FDA (2004) points that E. coli O157:H7, Salmonella spp., Cryptosporidium parvum, Listeria monocytogenes, metal contamination and pesticide residues are potential contaminants in acidic juices, such as lime and lemon.

Ingredients: Yoghurt Lime Juice Garlic Root ginger Cumin Coriander Garam Masala Paprika Salt Black pepper Chicken breasts Butter Lemon juice Cream Basic sauce Table 5: ingredients.

6.

Process Flow Diagram and On-site Confirmation

The process flow diagram to produce the butter chicken is presented below in figure 4 and it is necessary to validate it by going into the factory and comparing the processes presented in the diagram with the real process. If there are differences, it must be fixed to allow a real representation of the procedures in the factory. The conditions required to safely produce are discussed below for each relevant stage of the process:

•

Purchase, reception and inspection and storage conditions can be found in the sections above.

•

Defrost: according to the USDA (2013), using a leak-proof package and submerging it in cold water, which is faster than refrigerator defrosting and, therefore, presents a smaller risk of surface spoilage, as mentioned by James, S. J. and James, C. (2013).

•

Skewer and grill: 200°C for 4 minutes or golden-brown colour is achieved.

•

Cook: according to the USDA (2011), the minimum cooking temperature of chicken is 165°F (approximately 74°C), for 12 minutes, as presented in the Safwan’s cooking method.

•

Blast chill: below 5°C, which is the temperature for cold storage, within 2 hours or less, according to the Codex Alimentarius (1999), to avoid the danger zone (between 8°C and 63°C), as presented by the FSA (2018).

•

Mix and simmer: above 63°C for 1 min.

As explained by the FAO (1998) the layout of the factory is also required, which was already shown in the sections above. However, a new layout is proposed, which counts with measures to increase the safety of the factory and it presented in the figure 5 below. The main alterations are regarding the storage, waste and rubbish disposal areas in order to difficult access to the factory by pests and to reduce the risk of crosscontamination between the food being produced and waste and rubbish. The alteration of the entrance, so the employees must pass through a changing room to enter the factory. This way they will be obligated to change clothes and remove jewellery, watches and other objects that are not allowed in the food processing areas.

Figure 4: flowchart.

Figure 5: proposed layout.

7.

Hazard Analysis

The hazards identified for each ingredient and process are presented in the table 6 and 7 below. The CCPs are defined in table 8 using the decision tree present in Appendix 1. Once the CCPs are identified it is necessary to determine the critical limits, monitoring procedures, corrective actions and record keeping, which is shown in table 9.

Ingredients

Microbiological Hazard

Controlled at

Chemical Hazard

Yoghurt

Campylobacter, Listeria, Salmonella, verotoxigenic E. coli (VTEC), Staphylococc us aureus, and Bacillus cereus

Supplier GMP; CCP2

Allergen from cross-contamination, cleaning chemicals, mycotoxins1

Cream Butter

Chicken breasts

Salmonella and Campylobacter

Supplier GMP; CCP3

E. coli O157:H7, Supplier Salmonella spp., GMP; CCP3 Lemon juice Cryptosporidium parvum, Listeria monocytogenes Supplier Bacterial spores and Salt GMP; CCP3 rodent excrement

Pesticides, antibiotics, hormones, toxins, fertilizers, fungicides, heavy metals, colour additives, inks, indirect additives, packaging materials2

Controlled at

Supplier GMP

Supplier GMP

Physical Hazard

Metal, glass, plastic1

Metal, glass, plastic, bone, stones2

Controlled at

Supplier GMP, CCP6

Supplier GMP, CCP6

Lime Juice

Garam Masala Cumin Coriander Paprika Black pepper

- Bacillus cereus and members of Enterobacteriaceae - Rodent excrement

Supplier GMP; CCP3

Pesticide residues

-

Pesticide residues, heavy metals, cleaning chemicals, allergens3

Supplier GMP Supplier GMP

Supplier GMP

Metal fragments

Supplier GMP, CCP6

Dirt, stones

Supplier GMP

Glass, ceramic, brittle, metal, stones, dirt3

Supplier GMP, CCP6

Root ginger

Bacillus cereus, Clostridium perfringens and Salmonella spp4

Garlic

E. coli and Salmonella spp.5

Supplier GMP; CCP3

Insecticide, chlorine and aflatoxin4

Supplier GMP

Metal4

Supplier GMP, CCP6

Supplier GMP; CCP3

-

-

-

Table 6: ingredients hazards.

1FDA

(2007)

2USDA

(1997)

3American

Spice Trade association (ASTA) (2015)

4Kaeomalai, 5World

S. and Rawiyan, P. (2004)

Health Organization (2008)

Processes

Microbiological Hazard (M)

Chemical Hazard (C)

Reception and inspection

Failure to detect deterioration

-

Cold storage

Poor temperature control could allow microbial growth

Contamination with cleaning chemicals due to poor cleaning

Frozen storage

Poor temperature control could allow microbial growth

Contamination with cleaning chemicals due to poor cleaning

Dry storage

Poor pest control could lead to contamination with pests and it’s excrements

Contamination with cleaning chemicals due to poor cleaning

Packaging removal

Contamination with microorganisms present outside the package

-

Weight

Contamination with microorganisms due to poor cleaning

Marinade mix

Microbial growth due to increase in temperature

Defrost

Spoilage and microbial growth

Contamination with cleaning chemicals due to poor cleaning; Crosscontamination with allergen Contamination with cleaning chemicals due to poor cleaning; Crosscontamination with allergen -

Physical Hazard (P) Inadequate procedure could lead to contamination with dirt, package pieces, etc.

Inadequate storage conditions could allow contamination with package, glass, brittle Inadequate storage conditions could allow contamination with package, glass, brittle Inadequate storage conditions could allow contamination with package, dirt, glass, brittle Contamination with packaging pieces due to inadequate procedure Contamination with dirt or equipment pieces due to poor cleaning and maintenance

-

-

Simmer and mix

Skewer and grill

Cooking

Blast chill

Packaging

due to long exposure to temperatures higher than 5°C Potential microbial growth if temperature is below 63°C Inadequate inactivation of microorganisms due to low temperature Inadequate inactivation of microorganisms due to low temperature Microbial growth due to failure to chill the food under the specified time Spoilage and microbial growth due to poor temperature control

-

Metal contamination due to wear

-

Metal contamination due to wear

-

-

-

-

-

Contamination with packaging pieces

Metal detection

-

-

Failure to detect metal due to poor maintenance

Distribution

Spoilage and microbial growth due to poor temperature control

-

-

Table 7: process hazards.

Processes Reception and inspection Cold storage Frozen storage Dry storage Packaging removal Weight Marinade mix Defrost Mix and simmer Skewer and grill Cooking Blast chill Packaging Metal detection Distribution

Hazard category

Question Question Question Question 1 2 3 4

M and P

Yes

Yes

M, C and P M, C and P M, C and P

Yes Yes Yes

No No No

Yes Yes Yes

Yes Yes Yes

M and P

Yes

No

Yes

Yes

M, C and P M and C M

Yes Yes

No No

Yes Yes

Yes Yes

M and P

Yes

Yes

M and p

Yes

No

M M M and P

Yes Yes Yes

Yes Yes No

P

Yes

Yes

M

Yes

Yes

CCP? CCP1 -

CCP2 Yes

Yes CCP3 CCP4

Yes

Yes CCP5 CCP6 Table 8: CCPs identification.

Hazard

CCP

Critical limit

Ingredients deterioration

Reception and inspection

No signal of deterioration (change of colour, odour, etc)

Microbial growth and metal contamination

Mix and simmer

72째C for at least 15 seconds1

Inefficient inactivation of microorganisms

Cooking

74째C for 12 minutes

Microbial growth

Blast chill

Achieve 5째C before 2 hours of chilling

Metal fragments

Metal detection

Particles bigger than 0.5mm of diameter2

Microbial growth

Distribution

Below 5째C during the transportation

Monitoring procedures Visual monitoring before accepting the ingredients Temperature and process time monitoring

Corrective actions If any ingredient was wrongly accepted, remove and dispose it.

Adjust time and temperature to the correct value and hold the products suspected of deviation for inspection

Temperature and Adjust time and temperature to the correct value process time and hold the products suspected of deviation for monitoring inspection Temperature and Adjust chilling ratio and hold the products suspected process time of deviation for inspection monitoring Parameters Adjust the parameters and hold the products checking regularly suspected of deviation for inspection Temperature monitoring

Adjust temperature of the refrigerator and bring back the finished products for inspection Table 9: HACCP Plan.

1The

Dairy Products (Hygiene) Regulations 1995

2Kaeomalai,

S and Rawiyan, P. (2004)

8.

Validation and Verification of the HACCP Plan

The FAO (1998) describes the verification of the HACCP plan as a necessary activity to determine if the plan is working properly, for example if corrective actions are effective if a critical limit is exceeded.

The verification should involve actions as validation of the HACCP, which consists in review the work done and ensure that it is based in current good science and information. In addition, validation can be characterized as a step to ensure that the HACCP plan works, as stated by Wareing, P. (2010).

HACCP system audit, which consists in observations, interviews and review of records in order to identify if the measures and actions recommended by the HACCP plan have been implemented, as presented by FAO (1998).

The FAO (1998) states that calibration of equipment should be done in an interval that allows the machines to keep the accuracy and must be always recorded.

Finally, sample analysis helps the verification procedure by providing information to define if the food is being safely produced, as explained by the FAO (1998).

All the mentioned activities should follow a schedule or be done if there is any change in the process or factor that could influence the food safety and the actions must be recorded.

9.

Documentation and Record Keeping

Wareing, P. (2010) states that all stages of the HACCP development must be recorded and are useful internal, external and customer audits and in case of litigation.

The same author explains that records usually are maintained for at least a year after the shelf-life date of the product. Therefore, all the documents produced by this study must be kept by the Safwan’s Cury Paradise and new documents, generated by recording the processes, auditions, changes in processes, must be systematically stored and available to relevant members of staff, as presented by Wareing, P. (2010).

10. Recommendations

In conclusion, as already mentioned above, it is essential that the management supports not only the implementation of the HACCP system but also a culture of safety in order to be successful in the implementation and production of safe food. This will result in a more efficient process and better image to the consumers. However, the company cannot only be based on the present report, in order to achieve a state of continuous improvement it is necessary that management and employees are always alert to changes in the process and introduction of new method or products.

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12. Appendices 12.1.

Appendix 1: decision tree