HACCPDesignForAppleJuice.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, 2015IntroductionHazard Analysis and Critical Control Point (HACCP) is a concept in the field of food production, which developed in the late 1960s. It is on the basis of r

2、ecognized principles to achieve a high level of good safety management. HACCP system aims to reduce or eliminating hazards to an acceptable level that is quite essential to food manufacturing (Ropkins and Beck, 2000). HACCP used for detecting the hazards that may occur in the whole chain of food pro

3、duction and adopt preventive control measures to avoid the risks happening (Mortimore, Wallace and Cassianos, 2008). The function of HACCP on prevention of hazards reduces the dependency on end-product testing and traditional inspection (Peter, 2009). Instead, controls are transferred to the beginni

4、ng stage during production. Now, HACCP system has achieved international acceptance and this qualified system was recognized as an efficient measure of ensuring food safety (ibid).Nowadays, an increasing number of people are concerned about safety and quality of food. Public consumers hope they can

5、buy food that is sanitary, uncontaminated, nutritious, safe to consume, and meeting the quality standard (Early, 1995). Regarding daily food, beverage especially soft drink accounts for a large proportion in drinks market. The objective of this study aims to reduce or eliminate potential hazards, by

6、 means of developing a HACCP plan system with a series of monitoring and control measures, to prevent the consumers who consume the pressed apple juice.1. HACCP TeamA reasonable and convincing HACCP team should be built to monitor and develop an effective HACCP plan. All team members have a responsi

7、bility to complete food hygiene training to accomplish their tasks, and they should understand appropriate product-specific knowledge and expertise. A complete HACCP team includes many different and significant parts, including (FSA, 2015):l Team leader (person responsible for implementing HACCP): M

8、ayl Scribe: Helenl Sanitation Expert: Toml Processing line representative: Jerryl Hygiene Manager: Tonyl Product Specialist: Benl Packing and distribution expert: Kevinl Quality Assurance/Technology Specialist: Lucyl Food Safety Director: Victoria2. Pre-requisite Programs (PRPs)HACCP systems are des

9、igned to identify and analysis food safety hazards associated with products during the whole product processing. To ensure an effective HACCP system for apple juice, it should establish a firm foundation of compliance. These practices are considered to be pre-requisite to develop efficiently and imp

10、lement HACCP plans, and they are also can be screen out general hazards and reduce the number of CCPs (Gaze R., 2003). Besides, pre-requisite programs (PRPs) cover all areas in food production to support environment and operation condition and achieve safety of products (CFIA, 2011). The standard pr

11、e-requisite programs should include following aspects (Juice HACCP Alliance, 2002).Good Manufacturing Practices (GMP)GMP is one of the most important tools for food processing facility that helps for the production of high quality and safe juice products. It also provides the basis for product safet

12、y in the Hazard Analysis and Critical Control Point. GMP is often referred to the practices and procedures performed by food processor, and it may refer to the people, facility, process and environment in the processing line of juice (University of Nebraska, 2005).Good Hygiene Practices (GHP)Good Hy

13、giene Practices are necessary to ensure that there are complete and proper training schedule in the food industry including different levels of training programs and efficient operation facilities. GHP is often linked with staff training, hygiene condition of individual, control of equipment, which

14、used to reduce pathogenic hazards (Shafer, 2012).Good Agricultural Practices (GAP)Good agricultural practices as guidelines are vital to decreasing microbial contamination of raw agricultural products in food factory (Devon et al., 1999). It includes water management, temperature control, pest contr

15、ol, storage conditions management, facility sanitation, and distribution line (Rippen, 2007).Standard Operating Procedures (SOPs)SOP is prior to Sanitation Standard Operating Procedures (SSOP) (CFIA, 2014). It concentrated on control and monitors individual operations to ensure devices linked with p

16、roducts eligible develop and implement. Besides, SOP can control microbial hazard and prevent cross-contamination of juice through building appropriate operation line and improving procedures (Ba, 2006). 3. Product DescriptionTable 3.1 Product DescriptionName of productPressed apple juice (Tropicana

17、)DescriptionPure squeezed fruit, not from concentrateAverage nutrition values per 200ml1EnergyFat of which saturatesCarbohydrate of which sugars2FibreProteinSaltVitamin C438kj/102kcal (5%)0g (0%)0g (0%)24.0g23.4g (26%)1.2g0.2g0g (0%)82mg (103%)1Average serving. This pack contains 5 servings.2Contain

18、s naturally occurring sugars from juice.Chemical attributepH: 4Aw: 0.85Brix: 12Microbiological limitsPatulin: below 6g/kgProcessingRaw apple sorting, peeled, squeezed and then handle with filtration and dissolution. Pasteurization and filling will be conducted in final stagePackagingPackaged into 1

19、litre Pure-Pak classical cartonConditions of storageKeep in refrigerated below 4Shelf life30 days in a chilled environmentInstructions on the labelAlways store in refrigeratorShake well before servingUse within 5 days of openingConsumer groupGeneral populationRecommendation of further processing req

20、uired before consumptionStraight(Source from: Morrison, 2015)4. Process Flow ChartReceiving raw applesRaw apples storage74.1 Flow ChartSortingRemove debrisSelectingBrushInspectionRinsedWashingDrainedSqueezing0-5DistributionRefrigerate storageLabellingMetal detectionReceiving packaging materialsDry s

21、torageSealing8030FillingCooling72, 6s 60sPasteurizationWater, Sugar and VCIngredients blending50-55 2hUltra-filtrationEnzyme treatmentPreliminary filterFiltration4.2 Production ProceduresFirstly, apple juice needs to use the mature apple. The color, smell, harvest, quality and shelf life of the fina

22、l products could be affecting by raw apples types, maturity and storage time, therefore, the raw apple must supply by the approved supplier who can provide the high-quality raw materials. The reception area receives the goods must under the sanitary and safety conditions, to ensure the product low r

23、isk. If the product does not comply with the requirements, reception staffs must contact the supplier immediately, and the substandard products should be rejected. Raw apples should be stored in an optimum condition in order to prevent contamination or growth of microorganisms. Below 7 and 80% to 85

24、% relative humidity is the good condition of inhibiting microorganism growth and contamination, it is beneficial to cool and refrigerate raw apples to avoid yeast, mold and microbial as well (Baert et al., 2011). In order to eliminate the rotten apple, which may influence on the microbiological stat

25、us and the final quality, hence, the steps of selection and classification should be done before washing. Unsatisfied apples should be discarded in this step. Similarly, washing step uses roller brushes not only to remove apples surface dirt but remove the pesticide residues. Squeezing can cause phy

26、sical changes in the cell tissue of apple and oxidation reaction and pectin degradation happen immediately, which is beneficial to the final product quality.Filtration includes preliminary filtration, enzyme treatment and ultrafiltration; it is a step can make the product separation pulp and juice.

27、Separating bigger particles and foreign bodies should be used the preliminary filter to separate the liquid and solid (He et al., 2005). Then, under the temperature condition that about 50-55 for 2 hours, the output of apple juice can be increased by pectolytic enzyme and amylase, because the pectin

28、 could be broken down into the smaller soluble molecules under this situation, which can prevent the product curdling as well (Onsekizoglu et al., 2010). Ultrafiltration is further filtered the juice in the suspended objects in order to get a better quality of the final product, the metal debris and

29、 other impurities can be in this step will be removed as well (Cindri et al., 2011).Before the step of pasteurization, the filtered apple juice needs to mix with water, sugar, Vitamin C (Tropicana. 2014). The water source must avoid the potential risks, according to the relevant safe water standard.

30、 Sugar and Vitamin C should be supplied by an approved supplier to minimize the possible danger. Also, all materials must conform to the relevant food law. Juice must be pasteurized before filling processing, for 72 6 seconds, in order to eliminate the bacteria to health and safety of the final prod

31、uct, then the product need to rapid cooling to 30 in order to prevent juice quality affected, and then fill in packing.Filling step should be in sterile under the conditions of safe operation and the temperature is 80 (Van et al., 2005), because of the higher temperature will lead to boil juice, aff

32、ect the quality. Also, the packing materials could through heating, disinfector, ultraviolet irradiation, or a combined process to ensure safety and sanitary (He et al., 2005). In the process of production, if the metal pieces in the apple juice, can lead to serious threat, but pieces of metal that

33、can be detected through the metal detector and discarded in a timely manner (zolu and Bayndrl 2002). At last, before the apple juice transport to the retailers, the final products should be stored in a high sanitary level warehouse at 0-5 in order to keep the quality of apple juice and avoid growth

34、of the microorganisms (Welke et al., 2009). Similarly, the responsible for the transportation partners need to provide sanitarily and safety freight vehicles with refrigerator, to ensure that the quality of the products during the delivery. 5. Hazards AnalysisAfter identification of the hazards for

35、each process, according to the seven principles of HACCP, the following step is to determine the hazards need to be included. On the one hand, it should be highly concerned if there is an imminent risk to the public. One the other hand, the good practice control needs low concern (Mortimore et al.,

36、2008). The hazards justification for Pure-Pack apple juice is listed below by this principle. The hazards during the process of producing apple juice can be divided into three aspects: physical, chemical and biological.5.1 Biological Hazards5.1.1 E.coli O157:H7E.coli O157:H7 was known as one of the

37、worst types of E.coli serotype. It can grow in the environment from 7C to 50C, with the optimal temperature from 30C to 42C, and survive in acidic foods like apple juice with pH of 4.0-4.5 (Marriott and Gravani, 2006). E.coli O157:H7 can produce a toxin called Shiga toxin, causes severe foodborne di

38、sease sometimes can cause kidney failure, bloody diarrhoea and even death (Foodsafety, 2015). It mainly derives from contaminated foods, contaminated water. Recently, more foodborne outbreaks showed they are associated with fruits and vegetable consumption (WHO, 2011). This kind of bacterium is kill

39、ed by cooking foodstuffs until the temperature reaches 70C or higher. Thus, in terms of apple juice, E.coli O157:H7 always presences in unpasteurized fresh apple juice, which act as the vehicle for foodborne diseases (Buchana, Edelson and Snipes, 1998).5.1.2 SalmonellaSalmonella belongs to the gram-

40、negative rod, which is capable of growing in a broad range of temperature from 6C to 46C (Brands and Alcamo, 2006). Several Salmonella serotypes are available to grow with the scope of pH values from 3.7-9.5, with the optimum 6.5-7.5 (FoodSafetyWatch, 2013). Salmonella disease usually characterized

41、by abdominal pain, diarrhoea, fever and vomiting, but most patients will recover in 2-7 days without medical treatment (WHO, 2013). People usually get salmonella by consuming contaminated food. Salmonella can survive in the gut of farm animals, which may affect the products of poultry, eggs, meat an

42、d milk. Vegetables and fruit can also be infected by contacting with sewage in the water or manure in the soil (NHS, 2014). Many fruit juice manufacturers tend not to use thermal treatment to sterilize juice, owing to the loss of nutritional value and sensory qualities (Gabriel and Nakano, 2009). Ho

43、wever, unpasteurized juice may carry salmonella through an indirect way. 5.1.3 Listeria monocytogenesContaminated food with the bacterium Listeria monocytogenes can cause serious foodborne illness (Schlech III, Lavigne and Bortolussi et al., 1983). The disease mainly affects pregnant women, infants,

44、 older adults, and adults with adults with low immunity (Silk, Date and Jackson et al, 2012), shown as headache, stiff neck, confusion, weakness, and convulsions in addition to fever and muscle aches (Centers for Disease Control and Prevention, 2013). Listeria monocytogenes was identified as a foodb

45、orne pathogen associated with juice safety along with Salmonella and E.coli O157:H7 in the final ruling stated in the Federal Register FR, although it has not been directly pertinent to foodborne outbreaks related with juice (Gabriel and Nakano, 2009).5.1.4 Cryptosporidium parvumCryptosporidium parv

46、um is a kind of parasite can cause mild or even severe foodborne illness to humans (Fayer, Speer and Dubey, 1990). For humans with weak immune system, the symptoms of cryptosporidiosis are generally mild and self-recovery within 1-2 weeks; however, illness is often chronic and life-threatening to im

47、mune-compromised patients, such as AIDS patients (Fayer and Ungar, 1986). The way of C. parvum transmission is usually by the fecal-oral route. Commonly, drop apples been used for apple juice making in the practice, pathogens will be spread by this source (Besser, Lett and Weber, 1993). Apples are a

48、lso contaminated in stored or transported rooms that contain manure, or by contaminated water washing or touched by workers hands that carrying pathogens (Deng and Cliver, 2000). However, the available scientific literature suggests that C. parvum oocysts may be more resistant to thermal processing than E.coli O157:H7, Salmonella and Listeria monocytogene (Deng and Cliver, 2001).5.1.5 Control Measures for Biological HazardsAccording to WHO (2013), five key practices should be conducted to prevent microb