HACCP in Food Industry Application of HACCP in

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『 HACCP in Food Industry 』 -Application of HACCP in Japan In bottled products. Content ID : FY 2002 IN 11 NTT LEARNING SYSTEMS CORPORATION Produced by JICA April 15, 2004

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 [Compound factories, such as jam, juice, a fruit dessert, and a dressing] Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 2

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 View of Factory Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 3

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The process of the item made of the fresh orange 1 Arrival of orange Storage (refrigerator) Raw processing Drink preparation The check of the materials Check its quality and the number of materials The check of temperature The check of materials Keep 4℃ in the storage Check bruised materials Jam preparation Jelly preparation Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 4

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The process of the item made of the fresh orange 2 1/3 Drink preparation Jam preparation Jelly preparation Preparation room Use Room A. Preparation iron pot Use 200 L / 400 L steamy iron pot. Filling Semiｰ automatic machine for filling Machine for filling with Jam Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 130 cup sealer 5

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The process of the item made of the fresh orange 2 cover 2/3 Drink preparation Jam preparation Jelly preparation Cover a lid by hand Screw a lid by hand 131 cup sealer Sterilization by Sterilization boiling 85℃ for by boiling 30′ 90℃ for 30′ Sterilization by retort Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency Sterilization by boiling 85℃ for 30′ Sterilization by boiling 85℃ for 20′ 6

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The process of the item made of the fresh orange 2 Drink preparation Cooling Storage Jam preparation 3/3 Jelly preparation Natural cooling Water cooling 20℃ for 60′ Product storage room Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 7

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Fruit-juice drink HACCP generalization table Process list figure Harm and hazard Manageme monitoring/ Improv Verific nt standard measurement ation Materials arrival of goods Handling of Materials Freezing, dryness, and storage Choice of materials and Pretreatment Measurem ent of materials Preserve frozen at below 20 ℃ The Control Return The recor of edtemperature goods d of aband temp Spoilage in onmen eratu storage Check the t re date A bruise Preserve freshness is lost refrigerated at Check 5℃ with eyes. Freshness Mixing of and quality unsuitable substances Sorting on the Mistake of Check Aban stand Measurement with eyes. donm ent Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 8

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Fruit-juice drink HACCP generalization table Process list figure Mixture of Liquid dissolution Manageme monitoring/ Improv Verific Harm and hazard nt standard measurement ation Materials addition Damage of water The adjustment of sugar Add acidity Add wine Mistake of measurement Mistake of adding materials Check the concentrat ion of Chlorine Reach 85℃ 12% sugar content Check chlorine by thermomet er Aband Reco on rd of returne prepa dration goods Check by Aban the tool donm which ent shows sweetness Mistake of adding materials Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 9

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Fruit-juice drink HACCP generalization table Process list Checks, such as p. H etc. Addition of spice Cleaning a big pot Filling and measurement Improv Verific Harm and hazard Manageme monitoring/ nt standard measurement ation Measuring Check by Rep. H 3. 80 mistake PH inves tigati on Mistake of adding Check materials Disinfecti thermomet er and on with measuring around Mixing of machine 75℃ unsuitable water. Resubstances investi gation Mixing of unsuitable substances Materials are under weight. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 10

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Fruit-juice drink HACCP generalization table Process list Sterilization (CCP) Cooling Quality inspection Labeling and packing Manageme monitoring/ Improv. Verific Harm and hazard nt standard measurement ation Mistake of Sterilization time Bottle breakage Measuring mistake Mistake of labeling Sterilization The bacillus Aband by 85℃ hot on a check onmen water sheet t for 30 minute Check s Sterilization Aband with cold onmen water for 1 t hour The check Aban Record Refer to by the donm of good attached inspection ent sheet. machine Shipment Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 11

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Materials sorting and Pretreatment Process list Choice of materials Pretreatment monitoring/ Improv. Verific Manageme Harm and hazard nt standard measurement ation Mixing of unsuitable substances Sorting on Check the stand with eyes Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency Aban donm ent 12

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Materials sorting and pretreatment The skin is stripped, washed and cut. We are cautious of whether unsuitable substances are mixed. Alcoholic disinfection is carried out before breaking eggs. The salmonella of the surface of egg shell shall be sterilized. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 13

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Materials sorting and pretreatment Unsuitable substances are checked, using an inspection stand with penetrative light. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 14

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Washing before use of an iron pot Process list Improv Verific Harm and hazard Manageme monitoring/ nt standard measurement ation Disinfections by boiling water Mixing of unsuitable substances An iron pot should be sterilized with boiled water. Since it is an organic type, detergent can hardly be used. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 15

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Washing before use of an iron pot Process list Filling and measurement Improv Verifi Harm and hazard Manageme monitoring/ nt standard measurement catio n thermomet Readj Mixing of Around er ustme unsuitable 75 ℃ measurem nt substances short ent weight. machine Juice・dressings Fruit ・desserts Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 16

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Room for manufacturing Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 17

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Various measuring apparatus Process list Improv Verific Harm and hazard Manageme monitoring/ nt standard measurement ation Checks p. H etc. Measuring mistake PH 3. 80 The check by. Readj ustme p. H meter nt The procedure of proofreading (calibration) of p. H meter Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 18

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Boiling water sterilization (CCP) Process list Sterilization (CCP) Improv Verific Harm and hazard Manageme monitoring/ ement ation nt standard measurement Mistake of Sterilization time Breakage Sterilizatio The check Aband Steriliz n by 85 ℃ of a check onme ation nt record hot water sheet for 30 min. The time required depends on products. Sterilization tub (back ; thermometer) Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 19

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Sterilization by boiled water (CCP) The check list of temperature and time for sterilization (CCP) Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 20

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Cooling after sterilization Process list Cooling monitoring/ Improv Verific Manageme Harm and hazard nt standard measurement ation Cooling with cold water for an hour. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency Aban donm ent 21

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Cooling after sterilization After blowing away moisture and making it dry with air after cooling, it goes to a product warehouse. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 22

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 A product and inspection Then, it goes to a package center. Then, a product is stuffed after a label is stuck. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 23

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The check of the machine for catching an insect Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 24

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 The rule not to get dirty The handrail of a door is pushed by an elbow. Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 25

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 HACCP manual file Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 26

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Commencement-of-work check list Check date Year Month Date Inspector note: -- after [ a processing check ] evaluation (○or◎ -- indispensable) Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 27

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 Commencement-of-work check list (continuation) Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 28

"HACCP in Food Industry" -Application of HACCP in Japan In bottled products- Content ID: FY 2002 IN 11 『HACCP in Food Industry』 ○Produced Date：March 20, 2003 ○Name of the Lecturer(’s)(His or Her Company or University)：[ Mitsuo Kato (FOODS DESIGN CORPORATION)] ○Name of Copyright Holder：[ NTT LEARNING SYSTEMS CORPORATION] ○Address：[ 1 -6 -15 Minami Azabu, Minato-ku, Tokyo 106 -8566 Japan ] ○Telephone：[ +81 -3 -5440 -2716 ] Copyright. NTT LEARNING SYSTEMS CORPORATION Produced by Japan International Cooperation Agency 32