HACCPDesignForAppleJuice4996.docx

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1、Please Check the Repetition Rate After You Cite This ArticleThis article is from the submission of the University of Birmingham, 2015IntroduuctionnHazard Analyysis aand Crriticaal Conntrol Pointt (HACCCP) iis a cconceppt in the ffield of foood prroducttion, whichh deveelopedd in tthe laate 19960s. I

2、t iss on tthe baasis oof reccognizzed prrincipples tto achhieve a higgh levvel off goodd safeety maanagemment. HACCPP systtem aiims too reduuce or eeliminnatingg hazaards tto an accepptablee leveel that iis quiite esssentiial too foodd manuufactuuring (Ropkkins aand Beeck, 22000). HACCCP useed forr

3、deteectingg the hazarrds thhat may occcur iin thee wholle chaain off foodd prodductioon andd adoppt preeventiive coontroll meassures to avvoid tthe riisks happpeningg (Morrtimorre, Waallacee and Cassiianos, 20088). Thhe funnctionn of HHACCP on prreventtion oof hazzards reducces thhe deppendenncy onn

4、 end-produuct teestingg and tradiitionaal insspectiion (PPeter, 20099). Innsteadd, conntrolss are transsferreed to the bbeginnning sstage durinng prooductiion. NNow, HHACCP systeem hass achiieved interrnatioonal aaccepttance and tthis qqualiffied ssystemm was recoggnizedd as aan effficiennt meaasure

5、 of ennsurinng foood saffety (ibid).Nowadayys, ann incrreasinng nummber oof peoople aare cooncernned abbout ssafetyy and qualiity off foodd. Pubblic cconsummers hhope tthey ccan buuy foood thaat is sanittary, unconntaminnated, nutrritiouus, saafe too conssume, and mmeetinng thee quallity sstandaard

6、(EEarly, 19955). Reegardiing daaily ffood, beverrage eespeciially soft drinkk accoounts for aa largge prooportiion inn drinnks maarket. The objecctive of thhis sttudy aaims tto redduce oor eliiminatte pottentiaal hazzards, by mmeans of deevelopping aa HACCCP plaan sysstem wwith aa seriies off moniit

7、orinng andd conttrol mmeasurres, tto preevent the cconsummers wwho coonsumee the presssed appple jjuice.1. HACCP TTeamA reasoonablee and conviincingg HACCCP teaam shoould bbe buiilt too moniitor aand deevelopp an eeffecttive HHACCP plan. All team membeers haave a respoonsibiility to coomplette foood

8、 hyggiene trainning tto acccompliish thheir ttasks, and they shoulld undderstaand appproprriate produuct-sppecifiic knoowledgge andd expeertisee. A ccompleete HAACCP tteam iincluddes manyy diffferentt and signiificannt parrts, iincludding (FSA, 22015):l Team leeader (persson reesponssible for iimple

9、mmentinng HACCCP): Mayl Scribe: Heleenl Sanitattion EExpertt: Tomml Processsing lline rrepressentattive: Jerryyl Hygienee Manageer: Toonyl Productt Speccialisst: Beenl Packingg and distrributiion exxpert: Keviinl Qualityy Assuraance/TTechnoology Speciaalist: Lucyyl Food Saafety Directtor: Vicctoriaa

10、2. Pre-reqquisitte Proogramss (PRPPs)HACCP ssystemms aree desiigned to iddentiffy andd anallysis food safetty hazzards assocciatedd withh prodducts durinng thee wholle prooduct proceessingg. To ensuure ann effeectivee HACCCP sysstem ffor appple jjuice, it sshouldd estaablishh a fiirm fooundattion oo

11、f commpliannce. TThese practtices are cconsiddered to bee pre-requiisite to devvelop efficcientlly andd impllementt HACCCP plaans, aand thhey arre alsso cann be sscreenn out generral haazardss and reducce thee numbber off CCPss (Gazze R., 20033). Beesidess, pree-requuisitee proggrams (PRPss) covver

12、alll areeas inn foodd prodductioon to suppoort ennvironnment and ooperattion ccondittion aand acchievee safeety off prodducts (CFIAA, 20111). TThe sttandarrd pree-requuisitee proggrams shoulld incclude folloowing aspeccts (JJuice HACCPP Alliiance, 2002).Good Maanufaccturinng Praacticees (GMMP)GMP is

13、 one oof thee mostt imporrtant tools for food proceessingg faciility that helpss for the pproducction of hiigh quualityy and safe juicee prodducts. It aalso pproviddes thhe bassis foor prooduct safetty in the HHazardd Anallysis and CCriticcal Coontroll Poinnt. GMMP is oftenn refeerred to thhe praact

14、icees andd proccedurees perrformeed by food proceessor, and it maay reffer too the peoplle, faacilitty, prrocesss and envirronmennt in the pprocesssing line of juuice (Univeersityy of NNebrasska, 22005).Good Hyygienee Praccticess (GHPP)Good Hyygienee Praccticess are necesssary to ennsure that theree

15、 are compllete aand prroper trainning sscheduule inn the food iindusttry inncludiing diiffereent leevels of trraininng proogramss and efficiient ooperattion ffaciliities. GHP is offten llinkedd withh stafff traainingg, hyggiene condiition of inndividdual, contrrol off equiipmentt, whiich ussed too r

16、eduuce paathogeenic hhazardds (Shhafer, 20122).Good Aggricullturall Practiices (GAP)Good aggricullturall praccticess as gguidellines are vvital to deecreassing miicrobiial coontamiinatioon of raw aagricuulturaal prooductss in ffood ffactorry (Deevon eet al., 19999). IIt inccludess wateer mannagemeen

17、t, ttemperraturee conttrol, pest contrrol, sstoragge connditioons maanagemment, facillity ssanitaation, and distrributiion liine (RRippenn, 20007).Standarrd Opeeratinng Proocedurres (SSOPs)SOP is priorr to SSanitaation Standdard OOperatting PProceddures (SSOPP) (CFFIA, 22014). It cconcenntrateed on

18、conntrol and mmonitoors inndividdual ooperattions to ennsure devicces liinked with produucts eeligibble deveelop aand immplemeent. BBesidees, SOOP cann conttrol mmicrobbial hhazardd and preveent crross-ccontamminatiion off juicce thrrough buildding aapproppriatee operrationn linee and improoving pro

19、ceeduress (Ba, 20006). 3. Productt DesccriptiionTable 33.1 Prroductt DesccriptiionName off prodductPressedd applle juiice (Troppicanaa)DescripptionPure sqqueezeed fruuit, nnot frrom cooncenttrateAveragee nutrritionn valuues per 2000ml1EnergyFat of whiich saaturattesCarbohyydratee of whiich suugars22

20、FibreProteinnSaltVitaminn C438kj/102kcall (5%)0g (0%)0g (0%)24.0g23.4g (26%)1.2g0.2g0g (0%)82mg (1103%)1Averagge serrving. Thiss packk conttains 5 servvings.2Contaiins naaturallly occcurriing suugars from juicee.Chemicaal atttributtepH: 4Aw: 0.885Brix: 112Microbiiologiical llimitssPatulinn: bellow 6

21、g/kgProcesssingRaw appple soortingg, peeeled, squeeezed aand thhen haandle with filtrrationn and dissoolutioon. Paasteurrizatiion annd fillling will be coonductted inn finaal staagePackagiingPackageed intto 1 llitre Purre-Pakk classsicall carttonConditiions oof stoorageKeep inn refrrigeraated bbelow

22、 4Shelf llife30 dayss in aa chillled eenviroonmenttInstrucctionss on tthe laabelAlways storee in rrefriggeratoorShake wwell bbeforee servvingUse witthin 55 dayss of oopeninngConsumeer grooupGenerall popuulatioonRecommeendatiion off furtther pprocesssing requiired bbeforee conssumptiionStraighht(Sour

23、cee fromm: Morriison, 2015)4. Processs Floww CharrtReceiving raw applesRaw apples storage74.1 Floow ChaartSortingRemove debrisSelectingBrushInspectionRinsedWashingDrainedSqueezing0-5DistributionRefrigerate storageLabellingMetal detectionReceiving packaging materialsDry storageSealing8030FillingCooli

24、ng72, 6s 60sPasteurizationWater, Sugar and VCIngredients blending50-55 2hUltra-filtrationEnzyme treatmentPreliminary filterFiltration4.2 Prooductiion PrroceduuresFirstlyy, appple juuice nneeds to usse thee matuure appple. The collor, smelll, haarvestt, quaality and sshelf life of thhe finnal prroduc

25、tts couldd be aaffectting bby raww applles typees, maaturitty andd storrage ttime, thereefore, the raw aapple must supplly by thhe appprovedd suppplier who ccan prrovidee the high-qualiity raaw matterialls. The recceptioon areea recceivess the goodss mustt undeer thee saniitary and ssafetyy condditi

26、onns, too ensuure thhe prooduct low riisk. IIf thee prodduct ddoes nnot coomply with the rrequirrementts, receeptionn stafffs muust coontactt the suppllier iimmediiatelyy, and thhe subsstandaard prroductts shoould bbe rejjectedd. Raw aappless shouuld bee storred inn an ooptimuum connditioon in order

27、r to pprevennt conntaminnationn or ggrowthh of mmicrooorganiisms. Beloww 7 and 80% tto 85% relaative humiddity iis thee goodd condditionn of iinhibiiting microoorgannism ggrowthh and contaaminattion, it iss beneeficiaal to cool and rrefriggeratee raw applees to avoidd yeasst, moold annd miccrobiaal

28、as well (Baerrt et al., 2011). In ordeer to elimiinate the rrottenn applle, whhich mmay innfluennce onn the microobioloogicall stattus annd thee finaal quaality, hencce, thhe steeps off seleectionn and classsificaation shoulld be done beforre wasshing. Unsatiisfiedd applles shhould be diiscardded in

29、n thiss stepp. Similaarly, washiing sttep usses rooller brushhes noot onlly to removve appples surfface ddirt bbut reemove the ppesticcide rresiduues. SSqueezzing ccan caause pphysiccal chhangess in tthe ceell tiissue of appple aand oxxidatiion reeactioon andd pecttin deegradaation happeen immmediat

30、tely, whichh is bbenefiicial to thhe finnal prroductt quallity.Filtrattion iincluddes prrelimiinary filtrrationn, enzzyme ttreatmment aand ulltrafiiltrattion; it iss a sttep caan makke thee prodduct sseparaation pulp and jjuice. Separaating biggeer parrticlees andd foreeign bbodiess shouuld bee used

31、d the preliiminarry fillter tto sepparatee the liquiid andd soliid (Hee et all., 20005). Then, underr the tempeeraturre connditioon thaat aboout 500-55 for 22 hourrs, thhe outtput oof appple juuice ccan bee incrreasedd by ppectollytic enzymme andd amyllase, becauuse thhe pecctin ccould be brroken do

32、wnn intoo the smalller soolublee moleeculess undeer thiis sittuatioon, whhich ccan prreventt the produuct cuurdlinng as well (Onseekizogglu ett al., 20100). Ultraafiltrrationn is fuurtherr filttered the juuice iin thee susppendedd objeects iin ordder too get a bettter qqualitty of the ffinal produuc

33、t, tthe meetal ddebriss and otherr impuuritiees cann be iin thiis steep willl be removved ass welll (Cinndri et all., 20011).Before the sstep oof passteuriizatioon, the filteered aapple juicee needds to mix wwith wwater, sugar, Vitaamin CC (Troopicanna. 20144). Thhe watter sourcce musst avoidd the p

34、otenntial riskss, accorrding to thhe rellevantt safee wateer staandardd. Suggar annd Vittamin C shoould bbe supppliedd by aan appprovedd suppplier to minnimizee the possibble dangeer. Alsoo, all materrials must confoorm too the relevvant ffood llaw. Juicee must be paasteurrized beforre fillling proc

35、eessingg, forr 72 6 secconds, in oorder to elliminaate thhe baccteriaa to hhealthh and safetty of the ffinal produuct, tthen tthe prroductt needd to rrapid cooliing too 30 in oorder to prreventt juicce quaality affeccted, and tthen ffill iin paccking.Fillingg stepp shouuld bee in ssterille undder th

36、he connditioons off safee operrationn and the ttemperraturee is 880 (Van et all., 20005), becauuse off the higheer temmperatture wwill llead tto boiil juiice, aaffectt the qualiity. Also, the ppacking mmateriials ccould throuugh heeatingg, dissinfecctor, ultraavioleet irrradiattion, or a combiined p

37、processs to ensurre saffety aand saanitarry (Hee et aal., 22005). In thhe proocess of prroducttion, if thhe mettal piieces in thhe appple juuice, can llead tto serrious threaat, buut pieeces oof mettal thhat caan be deteccted tthrouggh thee metaal dettectorr and discaarded in a timelly mannner (zolu

38、 annd Bayyndrrl 2002). At lastt, beffore tthe appple jjuice transsport to thhe rettailerrs, thhe finnal prroductts shoould bbe stoored iin a hhigh ssanitaary leevel wwarehoouse aat 0-55 in orrder tto keeep thee quallity oof appple juuice aand avvoid ggrowthh of tthe miicroorrganissms (Wellke ett al.

39、, 20099). Simillarly, the respoonsiblle forr the transsportaation partnners nneed tto proovide sanittarily and safetty freeight vehiccles wwith rrefriggeratoor, too ensuure thhat thhe quaality of thhe prooductss duriing thhe delliveryy. 5. Hazardss AnallysisAfter iidentiificattion oof thee hazaards

40、ffor eaach prrocesss, acccordinng to the sseven princcipless of HACCCP, tthe foollowiing sttep iss to ddetermmine tthe haazardss needd to bbe inccludedd. On the oone haand, iit shoould bbe higghly cconcerrned iif theere iss an imminnent rrisk tto thee publlic. OOne thhe othher haand, tthe goood prra

41、cticce conntrol needss low conceern (Morttimoree et all., 20008). TThe haazardss justtificaation for PPure-PPack aapple juicee is llistedd beloow by thiis priinciplle. Thhe hazzards durinng thee proccess oof prooducinng appple juuice ccan bee diviided iinto tthree aspeccts: pphysiccal, cchemiccal an

42、nd bioologiccal.5.1 Bioologiccal Haazardss5.1.1 EE.colii O1577:H7E.coli O157:H7 was kknown as onne of the wworst types of E.coli serottype. It caan groow in the eenviroonmentt fromm 7C to 500C, wwith tthe opptimall tempperatuure frrom 300C to 42C, annd surrvive in accidic foodss likee applle juiice

43、wiith pHH of 44.0-4.5 (Maarriottt andd Gravvani, 2006). E.colli O1557:H7 can pproducce a ttoxin calleed Shiiga tooxin, causees sevvere ffoodboorne ddiseasse sommetimees cann causse kiddney ffailurre, blloody diarrrhoea and eeven ddeath (Fooddsafetty, 20015). It maainly derivves frrom coontamiinatedd

44、 foodds, coontamiinatedd wateer. Recenttly, mmore ffoodboorne ooutbreeaks sshowedd theyy are asssociaated wwith ffruitss and vegettable consuumptioon (WHHO, 20011). This kind of baacteriium iss killled byy cookking ffoodsttuffs untill the tempeeraturre reaaches 70C or higheer. Thhus, iin terrms off

45、applle juiice, EE.colii O1577:H7 alwayys preesencees in unpassteuriized ffresh applee juicce, whhich aact ass the vehiccle foor fooodbornne disseasess (Buchhana, Edelsson annd Sniipes, 1998).5.1.2 SSalmonnellaSalmoneella bbelonggs to the gram-negattive rrod, wwhich is caapablee of ggrowinng in a bro

46、oad raange oof temmperatture ffrom 66C to 46C (Brrands and AAlcamoo, 20006). SSeveraal Salmonnella serottypes are aavailaable tto groow witth thee scoppe of pH vaalues from 3.7-99.5, wwith tthe opptimumm 6.5-7.5 (FoodSSafetyyWatchh, 20113). SSalmonnella diseaase ussuallyy charracterrized by abbdomin

47、nal paain, ddiarrhhoea, feverr and vomitting, but mmost ppatiennts wiill reecoverr in 22-7 daays wiithoutt mediical ttreatmment (WHO, 2013). Peoople uusuallly gett salmmonellla by consuuming contaaminatted foood. SSalmonnella can ssurvivve in the ggut off farmm animmals, whichh may affecct thee prodducts of pooultryy, egggs, meeat annd millk. Veegetabbles aand frruit ccan allso bee infeected by coontactting wwith ssewagee in tthe