Student Works: HACCP ANALYSIS CASE 3: CANNED SARDINE IN TOMATO SAUCE GROUP 1

Product Chosen: Ayam Brand Canned Sardines in Tomato Sauce

Product Description: 1. Product Name 2. Composition / Raw Materials 3. Preservation Method Ayam Brand Canned Sardines in Tomato Sauce Sardines fish, tomato paste, palm oil, salt, xanthan gum. Canning is the preservation method. The purpose of canning is to use heat, alone or in combination with other means of preservation, to kill or inactivate all microbial contaminants, irrespective of their source, and to package the product in hermetically sealed containers so that it will be protected from recontamination. While prevention of spoilage underlies all cannery operations, the thermal process also cooks the fish (sardines) and in some cases leads to bone softening. If a thermal process is sufficient to fulfill the criteria of safety and prevention of nonpathogenic spoilage under normal conditions of transport and storage, the product is said to be "commercially sterile". In relation to canned foods, the FAO/WHO Codex Alimentarius Commission (1983) defines commercial sterility as "... the condition achieved by application of heat, sufficient, alone or in combination with other appropriate treatments, to render the food free from microorganisms capable of growing in the food at normal non-refrigerated conditions at which the food is likely to be held during distribution and storage". Although this definition specifically refers to "nonrefrigerated" conditions and thereby excludes those semipreserved and pasteurized foods in which refrigerated storage is recommended, publications by the Department of Health and Social Security in the United Kingdom and the Standards Association of Australia do not exclude refrigerated foods. According to these less restrictive interpretations, commercial sterility may then also encompass those foods which are intended to be stored at refrigeration temperatures; this implies that commercially sterile canned foods will be free from microorganisms capable of growing at ambient or refrigeration temperatures, whichever is considered normal. Tinplate, which is fabricated into two and three piece cans of a wide variety of shapes and sizes. Tinplate consists of a base plate of low-carbon mild steel, onto each surface of which is electrolytically deposited a layer of tin. Base plate gauge varies, depending on the size of the cans which are to be manufactured and their intended application. However, it is usually between 0.15 and 0.30 mm thick. Tin is applied to provide sacrificial protection

4. Packaging

5. Method of distribution 6. Method of storage

7. Intended Use

of the steel base -the tin layer gradually dissolves and passes into the surrounding solution, while the steel layer beneath remains protected. It is customary to use sulphur resistant (SR) lacquer systems to prevent the formation of unsightly, yet harmless, blue/black tin and iron sulphides on the plate. The dominant position of tin plate as the packaging material of choice for canned sardines has been challenged with the development of aluminium alloys. Alloys frequently lack the chemical resistance of pure aluminium. However, because they possess greater hardness than that of the pure metal, alloys are well suited to the construction of cans. The mechanical characteristics, lacking in pure aluminium yet required in the material for food cans, are obtained by the inclusion of small amounts of magnesium and manganese. Depending on the can size and the alloys used, the thickness of the aluminium in fish cans normally ranges from 0.21-0.25 mm. Double seaming in canning is to ensure hermetic seal to make product safer. The labelling of the tin is directly printed on the surface. Distribute by the distributor (A.Clouet & Co. (KL) Sdn. Bhd.) in Malaysia to retailer such as Tesco, Aeon, 7Elven, other supermarkets and convenient stores. Store in a cool place and away from direct sunlight. Refrigerate after opening and best consumed within 3 days. Can be directly consumed after opening. Eating alone or serve with other food is ideal for this product. Heating is encouraged as it is best to serve hot.

Process flow diagram for canned sardine in tomato sauce

Receiving

Cutting

Washing

Can filling and pre-cooking

Sauce filling

Seaming

Packaging

Storage

Dispatch

Hazard Analysis for Raw Materials and Packaging Raw Material / Packaging Material Sardine Potential Hazard (Biological-B, Chemical-C, Physical-P) B: C.botulinum, V. parahamolyticus, E. coli 0157:H7, fecal coliform and other microbes C: Histamine and Heavy metal Rationale for inclusion or exclusion as a Hazard Is this a Significant Hazard? Yes What measures can be applied to control this significant hazard? High temperature can reduce the number of microorganisms to minimum level. Is this raw material / packaging material a sensitive material? No

Inclusion: Fresh fish always contains some microorganisms.

Inclusion: History shown that histamine and heavy metal always found in sardines

No

P: Foreign matter

Tomato Paste

B: None C: Pesticide

Palm Oil

P: None B: None C: None

Inclusion: Sometimes foreign matter will stick with the fish. Exclusion: Strict control of suppliers under approved supplier program. -

Yes

Request certificate of Yes analysis from supplier. Conduct analysis to check the present of histamine and heavy metal. Reject the material if it is over the critical limits. Washing can help to No remove the foreign matter. No No

No No

No No No

No No No

Salt

Xanthan Gum

Can & Lid

P: None B: None C: None P: None B: None C: None P: None B: Pathogens post contamination after retorting from defected can and lid C: Bishenol-ADiglycidyl P: metal fragment contamination

Inclusion: Defect might be occur in can

No No No No No No No Yes

Visual inspection on the packaging

No No No No No No No No

Exclusion: Strict control of suppliers under approved supplier program. Inclusion: Metal fragment might be found as the can is made up of metal

No

No

Yes

Washing

No

Hazard Analysis for Process steps Process step Potential Hazard state whether biological, chemical or physical Rationale for inclusion or exclusion as a hazard Is this a What measure can be applied to Is this process a critical control point? (yes/no) Ensure the product received at between 1C and 5C YES

significant control this significant hazard? hazard? (yes/no)

Receiving

BIOLOGICAL Microbiological growth

Potential for pathogenic growth if product not kept under temperature control

YES

Sort/grade

BIOLOGICAL CHEMICAL PHYSICAL

Can be controlled by GMP implement Work procedures outline what staff are required to do

NO

Follow work procedures

NO

Washing

BIOLOGICAL Microbiological growth

Uses of non-potable water and/or unclean water No food safety hazard identified

YES

Ensure the uses of potable water by conduct the water testing

YES

Can filling and pre-cooking

BIOLOGICAL CHEMICAL PHYSICAL

NO

Follow legislative requirements

NO

Sauce filling

BIOLOGICAL

No food safety hazard

NO

Follow legislative requirements

NO

CHEMICAL PHYSICAL Seaming BIOLOGICAL Microbiological growth

identified

Pathogen contaminant due YES to seam failure

-Visual examination for double seam and other container defects at least every 30 minutes of continuous operation -Double seam teardown examination at intervals of sufficient frequency to ensure proper closure. -Interval not to exceed 4 operating hours (e.g. every 2 hours) Additional visual and teardown examinations to be made at the start of production, immediately after seamer jam, machine adjustment or a prolonged shutdown -Regular supervisor checks of operator performance

YES

Packaging

BIOLOGICAL

No food safety hazards identified

NO

Follow legislative requirements

NO

CHEMICAL PHYSICAL Storage BIOLOGICAL Microbiological growth Potential for pathogenic bacteria to grow if product not kept live at appropriate temperature Dispatch BIOLOGICAL Microbiological growth Hazard can be controlled by a work procedure NO Ensure the product is transported under appropriate temperature control (keep, and refer to temperature records) NO YES Store under refrigeration temperature 1C to 5C or seek alternative compliance for other temperatures YES

HACCP Plan Summary CCP No. & Significant Process Step Hazards Critical Limits What How Monitoring Freq. Who Corrective Action Verification (What/How/ Frequency/ Who) Receiving Microbiological Zero Raw material Spec inspection form Every order Line QC Reject the raw inspector materials, inform supplier, contact other suppliers Washing Microbiological Chlorine water Chlorine Chlorine At daily least Line QC Use inspector water Use clean and potable water Seaming Microbiological As per manufacturers specifications for particular can Double seam Visual and At least Line QC Stop production 30 inspector QC Manager Validation record Daily monitoring record Visual examination and filtered QC Manager Daily monitoring record QC Manager Raw record material Records

not less than level of the residual 0.2 ppm water testing

other examination every

container defects

minutes of continuous operation

Adjust Double seam teardown At intervals not exceed to 4 of and defective

seamer isolate stock

teardown records Calibration maintenance records Corrective action report Internal report External report HACCP record review audit audit and

and detain

examination hours operating

Storage

Microbiological

Refrigerated to 5C

Storage

Check storage

the Three times Line QC Throw away if QC Manager for daily inspector there microbial growth presents are

Daily monitoring record Temperature record

between -1C temperature

temperature

monitoring