The Design Of HACCP Plan

For Butter Plant

10/27/2019
1
 Profile
Name : Muhammad Ali Raza
Degree: B.Sc. Food Engineering
Semester: 6th
Presentation Neech: The Design Of HACCP Plan For Butter Plant
Course Code: FE-508
Course Title: Food Quality Control
Instructed By:- Mr. Hafiz Muhammad Ehtasham Akram

10/27/2019
2
 Overview
1. HACCP History & Introduction
2. HACCP Plan For Butter
3. HACCP Plan Identification
4. Assemble The HACCP Team
5. Develop And Verify Flow Diagram
6. Hazard Analysis
7. Flow Diagram With CCP And SSOP
8. HACCP Plan Summary Table

10/27/2019
3
 HACCP
HACCP is hazard analysis & critical control point.
It is a system that was developed for assuring Safe foods.
It provides precise process control measures for each step of the entire food
manufacturing process.
HACCP was first developed by a team of food scientists and engineers from
The Pillsbury Company, The Natick Research Laboratories And The
National Aeronautics And Space Administration in USA.

10/27/2019
4
 HACCP Plan For Butter
Following are the parts of HACCP plan for Butter plant.
1. HACCP plan identification page
2. Assemble the HACCP team
3. Describe food and its distribution
4. Production process with flow diagram.
5. Hazard analysis
6. Critical control point (CCP) determination
7. HACCP control chart.

10/27/2019
5
 Worksheet
Point system for development of the HACCP plan
HACCP Plan Identification Page
Product : Class Model for Butter
Product Codes Butter
Company Name Butter on way
Company Location Faisalabad, Punjab, Pakistan
Company Contacts Name: Khalid Mehmood
Phone: +923456640046 (Title: CEO)
Manufacturing Location Faisalabad, Punjab, Pakistan
Manufacturing Contact Name: Khalid Mehmood
Phone: +923456640046
Date HACCP Plan Preparation June,28 2015
Date HACCP Plan Revised July 24, 2016
Date HACCP Plan Approved July 29, 2016
10/27/2019
6
 Assemble HACCP Team
Product Butter
Date July 19,2018
Facility PC LHR
HACCP Team Leader/Coordinator Mr Ehtisham Akram
HACCP Team Name Title
Moin Owesi QA Manager Processing
Moazzam Expert
M Waseem Packaging Expert
Muhammad Ali Raza Maintenance Expert
Jahangir Sanitation Expert
Umair Quality Control Expert
Laraib Haider Laboratory Expert
M Arslan Distribution Expert
10/27/2019
7
 Product Description
Product name Butter

Fat, % 38.0–43.0
Acidity, % 0.56
Antibiotic Negative
Phosphatase Negative
Aflatoxin, ppb 0.50
Product characteristics
Pesticides residue < FDA standard
Coliforms (coli/g) >10
Staphylococci >10
Salmonella Negative
Listeria Negative

Packaging Plastic Box

Shelf life 9 Months
Distribution conditions >5ºC
10/27/2019
8
 Flow Diagram
Incoming
HTST Aging Churn
Cream

Metal
Packing Detector Butter Silo

Storage Distribution

05-Apr-19 Muhammad Waseem 9

 Hazard In Butter
Hazard
Processing steps Microbial Physical Chemical Control measure
Survival of Adequate receiving and
Foreign
Incoming Cream pathogenic Antibiotics storage.
materials.
organisms. Laboratory analysis sheet.

Survival of Strict adherence to HTST

Pasteurization Extraneous
pathogenic Not usually temperature and time.
HTST matter
organisms Sanitation of plates.

Outgrowth
Heavy metals, Effective pasteurization is
of spore-
Aging calcium Hardness Not usually critical in prohibiting spore
forming
of water germination and outgrowth.
pathogens. 10
10/27/2019
 Hazard Analysis
Hazard
Processing steps Microbial Physical Chemical Control measure
Contaminatio
n of Foreign Clean and sanitize.
Churn Not usually
pathogenic materials. Effective pasteurization
organisms
Cross-
contamination Program in place to prevent
Extraneous
Butter Silo with Not usually post pasteurization
matter
pathogenic contamination
organisms.

Metal
Calibrated and effective
Metal Detector fragments Heavy metals Not usually
metal detection.
contamination 11
10/27/2019
 Hazard Analysis
Hazard
Processing steps Microbial Physical Chemical Control measure
Hazardous
material from
Observe food hygiene
Packing Not usually the environment Not usually
practices.
or filling head or
operators..

Growth of
Extraneous Correct setting of freezer
Storage pathogenic Not usually
matter temperature
organisms

Pasteurized product
Distribution Not usually Not usually Not usually
contains no hazards
10/27/2019
12
 CCP Tree
Q-1 : Do Preventive Measure Exist For BCP
If Yes, Proceed For Q2, If No, is Control Necessary? If No, Not A
CCP.
Q2: Does This Step Eliminate/Reduce The Likely Occurrence Of BCP
Hazard To An Acceptable Level?
If No, Proceed For Q3, If Yes, That Is CCP.
Q3: Could Unacceptable BCP Contamination Occur?
If Yes, Proceed For Q4, Process Or Product, If No, Not A CCP.
Q4: Will Subsequent Step Eliminate BCP Hazard?
If No, CCP, If Yes, Not A CCP.
10/27/2019 13
 From CCP Tree, critical control points
Corrective
Process Hazard CCP Critical limit Monitoring action Verification
Cut in/Cut out
checks.
Flow divert
Pasteurization Recording vs.
Pasteurization Microbial >83°C for 25 sec Continuous recirculate and
temperature & Indicating
heat
Time thermometer
and calibration

Working of Reject, locate Detector

Metal detector Physical Limit of detectionContinuous
Metal detector source calibration

Hold product,
34–40 °F/3 days
Temperature & investigate Indicating
Storage Microbial 10–12 °F/9 3 Times a Day
Time cause, and thermometer
months
adjust
10/27/2019
14
 Flow Diagram With CCP
>83°C for
25 sec

Incoming
HTST Aging Churn
Cream

Limit of
34–40 °F/3 days 10–
12 °F/9 months detection

Storage Metal
Detector Butter Silo

05-Apr-19 Muhammad Waseem 15

 Conclusion
• Implementation of the HACCP system to the production of butter products
is a valuable tool for improving the safety and quality of the products.
• Chemical and microbiological results can be used as monitoring tools for
establishing the critical limits and taking needed corrective action.
• They can also be used to validate and verify the HACCP plan.
• Can improve It the overall performance of the butter plant.

10/27/2019
16
 Thanks

10/27/2019
17