Good Hygiene Practices along the coffee chain Module

Objectives and contents § Objectives § To make trainees aware of the importance of

Why flow diagrams? § How can we anticipate problems? § By thinking through each

A good flow diagram § Identifies all significant process steps used in production of

Constructing a flow diagram § Flow charts constructed on the basis of § Interviews

Evaluating process steps § For each step, all relevant process data should be considered

Completing Form 3 – example of boia production Coffee cherry Labelled jute bags 1.

What is a plant schematic? § Diagrammatic representation of establishment showing § Product, ingredient

Why a plant schematic? § Aids in the assessment of potential for cross contamination

Sample schematic – Plant for production of currants Finance / extension office Co-operative shop

On-site confirmation § Draft flow diagrams and plant schematics must be confirmed by on-site

On-site confirmation § Checks should be made at various times and through all operational

Summary § We have looked at § Understanding the importance of flow diagrams and

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Good Hygiene Practices along the coffee chain Module 4. 5 Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Objectives and contents § Objectives § To make trainees aware of the importance of an accurate flow diagram and plant schematic to identify potential hazards § To enable trainees to construct an accurate and complete flow diagram and plan schematic § Contents § Preparing a process flow diagram § Preparing a plant schematic § On-site confirmation of flow diagram 2 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Why flow diagrams? § How can we anticipate problems? § By thinking through each step and identifying potential hazards and possible control measures § Constructing an accurate flow diagram is an important task in the HACCP system 3 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

A good flow diagram § Identifies all significant process steps used in production of specific product being considered § Process step definition – ‘A point, operation or stage in the food chain, from primary production to final consumption’ § Enough detail to facilitate hazard identification without overburdening the plan 4 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Constructing a flow diagram § Flow charts constructed on the basis of § Interviews § Observations § Blueprints or other documents § Model form provided 5 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Evaluating process steps § For each step, all relevant process data should be considered § All ingredients and packaging § Time / temperature history including potential for delay § Product recycle / re-work loops § Equipment design features 6 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Completing Form 3 – example of boia production Coffee cherry Labelled jute bags 1. Harvesting 2. Receiving 3. Transport 4. Storing Other ingredients 5. Floatation separation … … … 25. Shipping Date: 7 Approved By: Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

What is a plant schematic? § Diagrammatic representation of establishment showing § Product, ingredient flow § Employee movement patterns 8 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Why a plant schematic? § Aids in the assessment of potential for cross contamination § Plant schematic may include § § 9 Routes of potential cross contamination Personnel routes Area segregation Flow of ingredients, packaging, waste materials Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Sample schematic – Plant for production of currants Finance / extension office Co-operative shop Processing lines Control Indoor storage Staff entrance Packaging 10 Outdoor storage Packaged product Dispatch / supplies in Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5) Staff changing rooms Fumigation chambers Receipt of currants QC

On-site confirmation § Draft flow diagrams and plant schematics must be confirmed by on-site inspection § All important process operations included § Movement of product and employees on the premises confirmed 11 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

On-site confirmation § Checks should be made at various times and through all operational periods § All members of the HACCP team should be involved in the confirmation of the flow diagram § Drafts adjusted according to findings of on-site inspection 12 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)

Summary § We have looked at § Understanding the importance of flow diagrams and plant schematics § Preparing flow diagrams § Preparing a plant schematic § Confirming accuracy of diagrams Next step: Applying HACCP Tasks 1 -5 to green coffee production 13 Module 4. 5 – Construct Flow Diagram & On-site Confirmation of Flow Diagram (Tasks 4 & 5)