HACCP PLAN FOR BAKED FOODS
Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
Langkah 1 : Establish the HACCP team
Name Dewi
Expertise/Position Food Tech. & HACCP specialist/
Position in the team Coordinator
QA Mgr.
Rahman
Engineering/Production Mgr.
Member
Putri
Microbiology/QC Mgr.
Member
Surya
Chemistry/Warehouse Mgr.
Member
Step 2 : Product Description
• • • • • • • • • • •
Name of product Composition Product characteristics Methods of processing Methods of preservation Primary packaging Conditions of storage Method of distribution Shelflife Specific labelling Instruction on the label
: cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu ::-
Step 3 : Identification of the Product’s Intended Use
• • •
Name of product Intended use Target consumer
: Cream-filled bread : Directly consumed : General public
Step 4 : Establish Process Flow Diagram Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg
Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C)
Filling with cream Packaging (PET bag/pouch)
Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 4 : Establish Process Flow Diagram Process flow diagram for the cream :
Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients
Beating (medium speed, 20 minutes) Storage (refrigerated)
Step 5 : On-site Confirmation of Flow Diagram : Bread Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Receiving (egg, water)
Dry storage at room temperature (25-300 C) Weigh all ingredients
Storage at 5-150 C
Mixing (sugar, salt and skim milk) Add shortening and egg
Blending (into creamed mixture) Add wheat flour, yeast, and cold water
Blending (into non-sticky dough) Round the dough
Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each
Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 5 : On-site Confirmation of Flow Diagram : Cream Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C)
Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Potential Hazard(s) B/C/P B
Description of Hazard Contaminated yeast (by spoilage or pathogenic m.o.)
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
B
Insects
Receiving of egg
B
Storage of egg
B
Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria
Weighing of all ingredients
P
Insect bone pieces
Mixing of sugar, salt, skim milk
P
Insect bone pieces, personal items
P
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step
Adding egg and shortening Adding wheat flour, yeast and cold water
Potential Hazard(s) Description of Hazard B/C/P B Contamination of pathogenic bacteria P Eggshell
B
Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces
Blending
Rounding the dough
Fermentation 1
Dividing the dough
Fermentation 2
P
P B
Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker
B
Contamination of spoilage m.o. from the air
B
Contamination of spoilage and pathogenic m.o. from the air and worker
B
Contamination of spoilage m.o. from the air
B
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.)
Name of Product : Cream-filled Bread Process Step Spreading with egg
Potential Hazard(s) B/C/P B
Baking
B
Cooling
B
Filling with cream
B
Packaging
B
Storage
B
Description of Hazard Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o.
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Receiving jelly mallow, butter, shortening
Potential Hazard(s) B/C/P -
Description of Hazard -
Storage
B C
Weighing all ingredients
-
Contamination of spoilage m.o. Decomposition of chemical compound -
Mixing
P
Personal item
Beating
P
Personal item
Storage
B
Growth of spoilage m.o.
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg, water
Storage of egg Weighing of all ingredients
Mixing of sugar, salt, skim milk
Adding egg and shortening
Adding wheat flour, yeast and cold water Blending
Rounding the dough
Potential Hazard(s) Preventive or Control B/C/P Description of Hazard Measures B Contaminated yeast (by spoilage Quality assurance (certificate of or pathogenic m.o.) analysis) from supplier P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs 0 B Growth of pathogenic bacteria Refrigerated storage (5-15 C), Label expired date. P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Eggshell Inspection of the ingredients (cracked eggs) P Insect bone pieces Filtering of wheat flour B Contamination of spoilage m.o. SSOP from the air P Personal item SOP for production area (no personal items are wore) B Contamination of spoilage & SSOP pathogenic m.o. from the air & worker
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage
Potential Hazard(s) B/C/P Description of Hazard B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Survival of spoilage m.o. B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage molds
Receiving jelly mallow, butter, shortening Storage
B
Contamination of spoilage m.o.
Weighing all ingredients Mixing Beating Storage
P P B
Personal item Personal item Growth of spoilage m.o.
Preventive or Control Measures SSOP SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Potential Hazard(s)
B/C/P B
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
P
Receiving egg, water
B
P
Storage of egg
B
Weighing of all ingredients
P
Description of Hazard Contaminated yeast (by spoilage/ pathogenic m.o.) Insects
Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items
Reasonably Significant likely to Severity hazard occur (Y/N)
Preventive or Control Measures
l
M
N
Quality assurance (certificate of analysis) from supplier
h
M
Y
Proper storage conditions (dry, clean), sealed packaging of the ingredients.
m
M
N
h
M
Y
Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs
l
L
N
Refrigerated storage (5-150 C), Label expired date.
l
M
N
Inspection of the ingredients, SOP for production area (no personal items are wore)
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Mixing of sugar, salt, skim milk
Potential Hazard(s)
B/C/P P
Description of Hazard Insect bone pieces, personal items Eggshell
Reasonably Significant Sevelikely to hazard rity occur (Y/N) l
M
N
m
M
N
Preventive or Control Measures Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs)
Adding egg and shortening
P
Adding wheat flour, yeast and cold water
P
Insect bone pieces
m
M
N
Filtering of wheat flour
Blending
B
Contamination of spoilage m.o. from the air Personal item
m
L
N
SSOP
m
M
N
Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air
l
L
N
SOP for production area (no personal items are wore) SSOP
l
L
N
SSOP
P Rounding the dough
B
Fermentation 1
B
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Reasonably Significant Preventive or SeveProcess Step Hazard(s) Description of Hazard likely to hazard Control rity \B/C/P occur (Y/N) Measures Dividing the dough B Contamination of spoilage and m L N SSOP pathogenic m.o. from the air, weighscale, and worker Fermentation 2 B Contamination of spoilage m.o. from the l L N SSOP air Spreading with egg B Contamination of spoilage and m H Y SSOP pathogenic m.o. from the air and worker Baking
B
Survival of spoilage m.o.
l
H
N
Cooling
B
m
M
N
Filling with cream
B
m
H
Y
SSOP
Packaging of bread
B
m
H
Y
SSOP
Storage and distribution
B
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
Correct time and temperature SSOP
m
M
N
Proper storage condition (dry, clean), expired date must be stated on the label
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening
Potential Hazard(s) B/C/P -
B
Description of Hazard -
Reasonably Significant Sevelikely to hazard rity occur (Y/N) -
m
H
Y
m
H
Y
-
Weighing all ingredients
-
-
-
-
-
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients -
Mixing
P
Personal item
l
M
N
SSOP
Beating
P
Personal item
l
M
N
SSOP
Storage of cream
B
Growth of spoilage m.o.
m
H
Y
Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
C
Contamination of spoilage m.o. Decomposition of chemical compound
Preventive or Control Measures
Principle 2 : Establishment of Critical Control Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients
Name of Product : Cream-filled Bread Ingredient
Potential Hazard (s) B
P1
P2
P3
CCP?
Y
Y
N
N
Wheat flour
P B
Y Y
Y Y
N N
N N
Yeast Egg
P B B
Y Y Y
Y Y Y
N N N
N N N
C
Y
N
-
Y
P B
Y Y
N Y
N
Y N
Sugar
Water
Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg
Process Step
P2
P3
P4
P5
CCP?
N
-
-
-
-
N
P
Y
Y
N
Y
N
CCP
Storage of egg
B P B
N Y N
Y -
N -
Y -
N -
N CCP N
Weighing of all ingredients
P
N
-
-
-
-
N
Mixing of sugar, salt, skim milk
P
N
-
-
-
-
N
Adding egg and shortening
P
N
-
-
-
-
N
Adding wheat flour, yeast and Cold water
P
N
-
-
-
-
N
Blending
B P
N N
-
-
-
-
N N
Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast
P1
Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B
Fermentation 1
Process Step
P2
P3
P4
P5
CCP?
N
-
-
-
-
N
B
N
-
-
-
-
N
Dividing the dough
B
N
-
-
-
-
N
Fermentation 2
B
N
-
-
-
-
N
Spreading with egg
B
Y
Y
N
Y
Y
N
Baking
B
N
-
-
-
-
N
Cooling
B
N
-
-
-
-
N
Filling with cream
B
Y
Y
N
Y
N
CCP
Packaging
B
Y
Y
N
Y
N
CCP
Storage and distribution of bread
B
N
-
-
-
-
N
Rounding the dough
P1
Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B C
Mixing
Process Step
P2
P3
P4
P5
CCP?
Y Y
Y Y
N N
Y Y
N N
CCP CCP
P
N
-
-
-
-
-
Beating
P
N
-
-
-
-
-
Storage of cream
B
Y
Y
N
Y
N
CCP
Storage of jelly mallow, butter, shortening
P1
Principle 3: Establishment of Critical Limits HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step
CCP No. 1 (C) 2 (P)
CL Antibiotic residue = 0 Cracked / broken egg = 0
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
3 (P)
Rh = 90-92% Time < 1 month SSOP = applied
Receiving egg
4 (P)
Cracked/broken egg = 0
Filling with cream
5 (B)
Holding Time
