HACCP in Food Industries Application of HACCP in

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『HACCP in Food Industries』 -Application of HACCP in Japan In Daily Product Produced by

『HACCP in Food Industries』 -Application of HACCP in Japan In Daily Product Produced by NTTLS CORPORATION Copyright. Japan International Cooperation Agency April 15, 2004

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Production site of

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Production site of milk HACCP Production of material Administration of steps from production site in farm to receiving inspection Expecting traceability Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 2

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- In farm, check

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- In farm, check the followings. ・ No contamination of agricultural drugs, insecticides, and chemical substances in material milk. ・No contamination of chemical substances and foreign matters at milking. ・ No contamination of chemical substances and foreign matters in storage site of material milk. ・Temperature management in storage site of material milk. ・ Temperature management in transportation to factory (recording was completed or not) Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 3

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- At receiving inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- At receiving inspection in factory, to transfer milk hygienically to material milk storage tank. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 4

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and CCP ※CCP in manufacturing milk Receiving → CCP ↓ Storage ↓ Filter ↓ Homogenize Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 5

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and CCP (continued) ↓ Sterilize → CCP (sterilization temp. and time) ↓ Cooling ↓ Package ↓ Inspection by metal detector → CCP Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 6

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and CCP (continued) ↓ Packing in box ↓ Store and shipping Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 7

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Material milk check

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Material milk check Contamination of antimicrobial substance (chemical hazard) Abnormal constituent (chemical hazard) Contamination of detergent and bactericide (chemical hazard) Pollution by pathogenic microbes (biological hazard) Pollution by septic microbes (biological hazard) Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 8

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- CL: no antibacterial

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- CL: no antibacterial substance should be detected. Object for monitoring: Antibacterial substance Method: Paper disc method Frequency: Operation for every tanker Personnel in charge: To be recorded by quality manager Person responsible to quality management inspects everyday and once a month. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 9

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sensory test At

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sensory test At opening lid, check external appearance , color, and taste. If required, close examination for confirmation. Alcohol test Inspection by method legally designated. Specific gravity, fat, and acidity Inspection by method legally designated. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 10

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Milk temperature Measure

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Milk temperature Measure with thermometer immediately after stirring (7 deg. C or lower) Antibacterial substance Inspection Total bacterial count Inspection by test method legally designated Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 11

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Temperature measurement of

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Temperature measurement of material milk (Standard of this factory is 6 deg. C or lower) Category Milk Check time 9: 30 10: 00 10: 30 10: 50 Temperature of material milk Inlet Outlet 6 deg. C or lower 3 3 Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 2 2 12

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management of factory Record of cleaning and washing Start End Time required Litmus paper test Acid operation date Line name Checkconfirming person Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 13

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management of factory Operation and record of CIP washing (automated washing at Clean In Place ) Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 14

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management of factory Connecting position of pipeline is important. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 15

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Internal hygienic management of factory Washing packing machine Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 16

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sterilization steps of

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sterilization steps of milk 130 deg. C, 20 sec. (UHT method) 75 deg. C, 15 min. (20 min. ) (HTST method) 63 deg. C, 30 min. UHT method= super high temperature sterilization method (heat at 80 deg. C for 20 sec) HTST method= high temperature short time sterilization method (heat 130 deg. C for 2 to 3 sec) Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 17

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sterilization steps of

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Sterilization steps of milk Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 18

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- a. Washing and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- a. Washing and sterilizing instrument, tank, and valves before use b. Confirming FDV ( Fill Drain Valve ) work c. Test and confirmation of fresh milk quality before sterilization (to stress to taste) d. If there is stored milk to be subjected to prolonged sterilization, inspection and confirmation of milk quality (to stress to taste) e. Confirmation of sterilization temperature and cooling temperature Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 19

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- f. Internal and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- f. Internal and external visual check of surge tank before use. g. Maintenance and inspection of sterilizer, homogenizer, tank, and valves. h. Confirmation of circulation condition of cooling water. i. Confirmation and correction of of concentration of CIP solution. j. Inspection of indication of thermometer and pressure gauge. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 20

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- k. Inspection, calibration

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- k. Inspection, calibration and replacement of performance of measuring apparati. l. Arrange, organize, and clean sterilization room. m. Management and confirmation of air shower room n. Protect from rats and insects in sterilization room. o. When deviation from management standard occurs, report immediately to person in responsible. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 21

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging a. Confirm

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging a. Confirm cleaned and sterilized state of filling machine. b. Confirm milk chamber and tasting test at start of filling. c. Maintenance and inspection of filling machine and confirmation of workability d. Test presence or absence of abnormal state of operation following filling start manual. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 22

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) e.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) e. Prevent contamination of packing material. f. Hygienic handling and hygienic storage of packing material out of set. g. Observe presence or absence of seal leak and state of packed shape. h. Inspect and confirm accuracy of filled amount. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 23

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) i.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) i. Inspection and confirmation of date printing j. Confirm workability of metal detector k. Prevent contamination of foreign matter l. Administration and confirmation of air shower room Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 24

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) m.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Packaging (continued) m. Arrangement, organizing, cleaning of room and drying floor. n. Prevention of rat and insect’s invasion in room o. Confirm opened or closed entrance door. p. When administration standard is deviated, Report immediately to person responsible to administration. Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 25

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Manufacturing steps and check list Example of manufacturing steps and HACCP for milk for drinking use. Refer to MS-Word format documents Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 26

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection items list

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection items list Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 27

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (1) No. 1 Item Score Remarks Are maintenance and inspection of facilities, machines, and tools conducted and recorded after administration standard ? (Administration standard should have method, frequency, name of personnel responsible, confirmation, way of recording. ) 2 Are maintenance and inspection of facilities, machines, and tools conducted systematically ? (For example, annual or monthly schedule) Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 28

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (2) No. Item 3 Are dissociation and inspection of machines and pinhole check of tank and plate conducted and recorded after administration standard and operational manual ? 4 Are oil supply to instruments conducted and recorded after administration standard? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 29

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (3) No. Item 5 Are inspection apparati (metal detector, weight checker, and date checker) confirmed and recorded for sensitivity and workability for each test piece ? 6 Are facilities, machines, tools, and places around them well cleaned appearing clean appearance without any stained spot? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 30

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (4) No. Item 7 Is there any abnormality in facilities, machines, and tools (Is there any abnormal sound, break, trouble, missing of any component, emergency treatment, oil leak? Is there leak from pump, valve, or piping system) ? 8 When any trouble is found, are there any records of situation, cause, treatment, time of stop, and way of preventing repetition? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 31

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (5) No. Item 9 Is there any change of facilities, machines, and tools (renewal and addition) ? When any change is carried out, are administration standard and operational manual changed to manage them? 10 Are measuring apparati and meters and volumetric measures (thermometer, pressure gauge, liquid surface meter, volumetric measures) calibrated and recorded periodically ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 32

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Maintenance and inspection of facilities, machines, and tools (6) No. 11 Item Score Remarks Are administration of tools and parts suitably carried out? Average score Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 33

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (1) No. Item Score Remarks [Standard] 1 Are cleaning and sterilizing machines and apparati are operated and recorded after administration standard and operational manual? (Method, detergent species, concentration, temperature, flow, time, frequency, personnel in charge should be indicated. ) 2 Are maintenance and inspection of facilities, machines, and apparati are operated systematically (annual and monthly schedule) ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 34

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (2) No. Item Score Remarks [Cleaning] 2 Are kind, concentration, temperature, flow, and time of CIP cleaning set suitably for each flow line? 3 Are concentration, temperature, and time of CIP detergent confirmed at fixed time and is operational record stored ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 35

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (3) No. Item 4 Can CIP flow be kept enough? Is CIP flow periodically confirmed? 5 Is there any place where insufficient cleaning caused by insufficient flow or liquid stay occurs ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 36

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (4) No. Item 6 Is abnormality such as stain of CIP tankcleaning solution confirmed at fixed time and is cleaning solution replaced periodically? 7 Is there any place where insufficient cleaning caused by insufficient flow and liquid stay occurs ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 37

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (5) No. Item 8 Is cleaning by hand operated and recorded after operational manual? 9 Is cleaning by hand operated by using work stand by no placing on floor? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 38

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (6) No. Item 10 Are places around apparati cleaned well to keep cleanliness? 11 Are detergent and bactericide stored by designating personnel responsible to administration and place of storage? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 39

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (7) No. Item Score Remarks [Sterilization] 12 For sterilization of line and apparati, is maintenance of predetermined temperature and time confirmed and recorded ? 13 For steam sterilization, is drain discharged from terminal without stay? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 40

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Cleaning and sterilizing machines and apparati (8) No. 14 Item Score Remarks Is concentration of chlorine water managed and recorded? Average score Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 41

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (1) No.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (1) No. Item 1 For material and product, inspection and recording are conducted after designated quality standard and inspection standard ( inspection items, method, frequency)? 2 Is quality standard and inspection standard suitable as standards to be applied? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 42

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (2) No.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (2) No. Item 3 Is how to treat material and product deviated from standard designated clearly or are treatment of those deviated correctly carried out? 4 Is inspection result fed back soon to employ for improvement ? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 43

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (3) No.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (3) No. Item 5 Does personnel responsible confirm inspection result? 6 Is inspection result of material and product ensured for reliability? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 44

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (4) No.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (4) No. Item 7 Is specific number of each product reserved as sample after standard to inspect and confirm? 8 Is personnel in charge to inspection subjected and recorded to suitable technical training (including sensory test training) and skill evaluation periodically? Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION Score Remarks 45

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (5) No.

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- Inspection (5) No. 9 item Score Remarks Are inspection apparati subjected to maintenance and administration after maintenance and administration manual or is calibration or replacement carried out suitable to record it? Average score Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 46

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- 『HACCP in Food

『HACCP in Food Industry』-Application of HACCP in Japan In Daily Products- 『HACCP in Food Industry』 ○Produced Date: [April 15, 2004] ○Name of the Lecturer(’s) (His or Her Company or University):[Mitsuo Kato (FOOD DESIGN CORPORATION)] ○Name of Copyright Holder: [Japan International Cooperation Agency] ○Name of Manufacturer: [NTT LEARNING SYSTEMS CORPORATION] ○Address:[1 -6 -15 Minami Azabu, Minato-ku, Tokyo 1068566 Japan] ○Telephone:[+81 -3 -5440 -2716] Copyright. Japan International Cooperation Agency Produced by NTT LEARNING SYSTEMS CORPORATION 47