UNIVERISTI KUALA LUMPUR MALAYSIAN INSTITUTE OF CHEMICAL AND

BIOENGINEERING TECHNOLOGY
(UNIKL MICET)

FOOD QUALITY & SAFETY MANAGEMENT SYSTEM

(CFB31003)
LECTURER: DR MASNIZA BINTI MOHAMED

SITI NOOR SHAZLEEN BINTI MASROF (55218117084)

HACCP PLAN

Product: FRESH- SQUEEZED ORANGE JUICE Plant:

Operational/ Hazard/ Monitoring/ Corrective Verification

Process Step Concern CCP/Type Critical Limit/Criteria Frequency Records Responsibility Actions Procedures

Sanitation Microbiological CCP1/ Clean, sanitized, properly Observe clean- Sanitation logs Supervisors Stop production Semi-annual
Programs pathogenic/ Prevention stored equipment ing/sanitizing & correct inspection
spoilage Prevention from overhead procedures/ daily
& Critically inspect
environmental contamination all areas/weekly
Hygienic Personnel Practices Critically inspect
all areas/monthly
Chemical Proper use & storage Check chemical
improper storage of chemicals levels/every 3 hrs
& use 200 ppm chlorine
or equivalent

Fruit Source Microbiological Use only high quality fruit Inspect & Inspection forms Graders/ Super- Reject poor Semi-annual
& Quality pathogenic/ Appropriate fertilizers observe visors quality fruit inspection
spoilage production &
handling
practices/daily
Chemical Proper use of Agr. chemical
Agr. chemicals

Raw Fruit Microbiological Clean/sanitized storage boxes Observe & Sanitation log sheet Supervisor Replace Semi-annual
Handling & pathogenic/ Refrigerate at 40°F or below inspect Temperature log uncleanable inspection
Storage spoilage operations/daily sheet Supervisor equipment
Check Correct &
storage room maintain temp
temperature control
/hourly

Fruit grading, Microbiological CCP2/ Grading - Fruit rejection Observe Check sheets Supervisor Re-grade or
Conveyance & Pathogenic/ Prevention standards operations/hourly reject
Washing Spoilage Inspection log Re-wash
Conveyance - Minimum Critical sheets
environmental contamination inspection/ daily
Log sheets
Chemical Washing/Rinsing - Proper 200 ppm
Improper use procedures Chlorine or
equivalent
rinse/each use

Juice Extraction Microbiological Clean/Sanitized equipment Visual Sanitation log sheet Supervisor Stop production
Pathogenic/ Prevent overhead inspection &/ and clean
Spoilage contamination observation of properly
equipment/daily
 HACCP PLAN

Product: FRESH- SQUEEZED ORANGE JUICE Plant:

Operational/ Hazard/ Monitoring/ Corrective Verification

Process Step Concern CCP/Type Critical Limit/Criteria Frequency Records Responsibility Actions Procedures

Juice cooling & Microbiological CCP3/ Cool to 40°F Temperature Temperature Supervisor Cool to 40°F
filling Pathogenic Prevention No overhead contam. of fillers recording/hourly Sanitation log sheet
Spoilage Clean/Sanitized equipment Visual
Inspection/daily

Juice storage Microbiological Maintain at 40°F or below Temperature Temperature log Supervisor Cool to 40°F
Pathogenic recording/hourly sheet
Spoilage

Table 1: HACCP PLAN SUMMARY FOR FRESH-SQUEEZED ORANGE JUICE

There are 7 principle of HACCP to prevent foodborne illness in food & beverages industry:

1. Identify hazard
2. Identify critical control point (CCP)
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Actions
6. Establish Verification Procedures
7. Establish Record Keeping Procedures
KEY STEPS IN A TEMPERATURE CONTROL SYSTEM

Use of time and temperature are the main cause of food deterioration. The process needs
to be analyzed properly to meet the correct temperature and avoid bad, polluted and
infected food. Temperature control system is one of the major safety tools that control
and maintain the temperature from causing any damage to food product. There are four
basic food safety principles to reduce the risk of foodborne illness which are clean,
separate, cook and chill.

Figure 1: Food Temperature Danger Zone

Based from the fresh squeezed orange juice HACCP plan, after extracting the orange
juice the juice undergoes cooling at 40º F. The storage of the orange juice is also
maintained at 40°F or below. This method is used to avoid microbial hazard (pathogenic
spoilage) and to prolong the shelf life of the fresh squeezed orange juice. From figure 1,
the suitable temperature for chilling and chilled storage is between 32 ºF to 40º F because
the microbe grows very slowly in these temperatures.
METHODS FOR THE SAFE STORAGE OF FOOD

Storage of food in a correct way is very important so that the food is safe to use at certain
point of time. The proper storage of food can save time, money, instant availability and
protects from spoilage and wastage of food. There are three type of food which are
perishable, semi-perishable and non-perishable food (Robbins,2019). There several
methods that can be used for safe storage as follows:

Correct temperature control: The correct temperature control for the proper storage of
food product need to be identified. Based from the HACCP plan above the temperature
needed to store the fresh squeezed orange juice is below 40°F because the microbe can
only grow very slow below this temperature and spoilage can be avoided.

Labelling: The food labelling is one of the important methods in storage of the food. The
labelling of food is important that help to guide when and which food to use and it also
use to ensure the expiry dates and ingredients of the food

Use by date: The ‘use by’ date is compulsory to be shown in labelling the food product.
Expiry date is important so that it can be protected from contamination of food by the
consumers or the company itself. It is advisable that food that had pass the expiry date is
not used even it still look edible and fresh to avoid any consequences.

Methods for the safe storage of fresh-squeezed orang juice is by chilling. To safely
refrigerate the orange (raw material) and orange juice is to set the fridge to a temperature
between 1°C and 4°C to make sure it stays below 5°C where microbes grow very slowly
at this temperature. Use separate refrigerators for orange (raw material) and orange juice
(product) to minimize cross-contamination. Next, avoid overloading the fridge or placing
food in front of the cooling unit to make sure there are plenty of room between foods to
allow air circulation (Burton,2019).
IMPORTANCE OF PERSONAL HYGIENE IN THE CONTROL OF FOOD
CONTAMINATION

Personal hygiene is very important in the control of food contamination to ensure that
those who come directly or indirectly into contact with food are not likely to contaminate
food by maintaining an appropriate degree of personal cleanliness and behaving and
operating in an appropriate manner. Food contamination by lack of personal hygiene can
cause foodborne illness. In fresh squeezed orange juice premises can achieve the
importance of Personal Hygiene according to the GOOD MANUFACTURING
PRACTICE (GMP) FOR FOOD MS 1514:2009 by washing hands thoroughly and
sanitizing to protect against contamination with undesirable microorganisms before
starting work. While handling food any jewelry must be taken off to avoid it fall into the
food or container and can cause contamination of the food. Furthermore, wear hair nets,
headbands, caps, beard covers, or other effective hair restraints to avoid any hair fall into
the food. Lastly, is to maintain adequate personal cleanliness such as short and clean
fingernails while direct handling the food. Training employees about the importance of
personal hygiene is very important to keep the of fresh squeezed orange juice production
to be safe for the consumers.
EVALUATE THE CLEANING AND DISINFECTION AS A PROCESS
SUPORTING SAFE FOOD PRODUCTION

Cleaning and disinfection process are a critical step in food production and is very crucial
to maintain and guarantee the safety of the food. Cleaning is the total removal of residues
and soil from surfaces, and make sure it is visually clean so that disinfection will be
effective. Without effective cleaning, disinfection will be compromised. Disinfection is
the process by microorganisms are killed so that their numbers are reduced so that it is
not harmful to the perishable goods (Care, 2015). Cleaning and disinfection are important
to reduce the risks from food hazards – food poisoning and foreign body contamination,
to meet specific customer requirements, to meet the requirements of food safety standard,
to maintain positive audit and inspection outcomes, to maintain product shelf-life and to
avoid pest infestation (Faul, 2019). To make sure that cleaning and disinfection as a
process supporting safe food production are by understanding various soil type and how
to get rid of it, why cleaning and disinfection is made and how detergents and
disinfectants work is keys to ensuring a safe and hygienic manufacturing environment in
the premises.
ASSESS PROBLEMS ASSOCIATED WITH PEST CONTROL IN FOOD
PREMISES

Pest control plan layout must be applied for the fresh squeezed orange juice premises.
The best pest control in food processing areas must be properly analyze and conduct. Pest
control should be done for prevention from food contamination. Pest control plan layout
act as a precaution to prevent pest such as cockroaches, fly, ants and mice in the food
premises. Pest can cause serious food contamination as a biological hazard if it has
contact with the food. According to the GOOD MANUFACTURING PRACTICE
(GMP) FOR FOOD MS 1514:2009 in pest control program there are ways to assess
problems associated with pest control in food premises. Firstly, buildings should be kept
in good repair and condition to prevent pest access and to eliminate potential breeding
sites. Holes, drains and other places where pests are likely to gain access should be kept
sealed. Secondly, the availability of food and water encourages pest harborage and
infestation in the premises. Potential food sources should be stored in pest-proof
containers and/or stacked above the ground and from walls and areas both inside and
outside food premises should be kept clean.

Thirdly, the monitoring and detection methods used should enable the sites of pest
harbourage and access to be identified and objective assessments of site environmental
conditions and pest population levels be made. Establishments and surrounding areas
should be regularly examined for evidence of infestation. A written analysis should be
provided, with details on problem areas within the establishment. Lastly is eradication.
Pest infestations should be dealt with immediately and without adversely affecting food
safety or suitability. Treatment with chemical, physical or biological agents should be
carried out without posing a threat to the safety or suitability of food.
JUSTIFY THE NEEDS FOR HYGIENIC DESIGN AND CONSTRUCTION OF
FOOD PREMISES

Hygiene need is the first counter measure that needs to be consider in the food factory or
any other related food service. The design and layout construction need to comply good
food practices, including protection of foodstuffs against cross-contamination an in
between operations. According to the GOOD MANUFACTURING PRACTICE (GMP)
FOR FOOD MS 1514:2009, the following specific conditions should be satisfied where
necessary to protect the safety and suitability of food:

a) the surfaces of walls, partitions and floors should be made of impervious

materials with no toxic effect in intended use;
b) walls and partitions should have a smooth surface up to a height appropriate to the
operation;
c) floors should be constructed to allow adequate drainage and cleaning;
d) ceilings and overhead fixtures should be constructed and finished to minimize the
build
e) up of dirt and condensation, and the shedding of particles. The drip or condensate
from fixtures, ducts and pipes shall not contaminate food, food-contact surfaces,
or food packaging materials;
f) windows should be constructed to minimize the buildup of dirt, be easy to clean,
and
g) where necessary, be fitted with removable and cleanable insect-proof screens;
h) doors should have smooth, non-absorbent surfaces and be easy to clean and,
where
i) necessary, disinfect; and
j) working surfaces that come into direct contact with food should be in sound
condition,
k) durable and easy to clean, maintain and sanitize. They should be made of smooth,
nonabsorbent materials, and inert to the food, to detergents and sanitizers under
normal operating conditions.
JUSTIFY THE IMPORTANCE OF TRAINING AS A QUALITY ASSURANCE
MECHANISM

Training is very important to make sure that the employees of the fresh squeezed orange
juice company understand what are going on in the food factory. Company need to train
their employees to maintain the quality of the production and quality services for
customer. According to the GOOD MANUFACTURING PRACTICE (GMP) FOR
FOOD MS 1514:2009, inadequate training and/or instruction and supervision of all
people involved in food related activities pose a potential threat to the safety of food and
its suitability for consumption. There are a lot of food safety training includes cleanliness,
pest control, food storage, preservation and personal hygiene. For example, hygiene
standard training is important for the company’s employee to comply with the standards
of GMP and HACCP and to maintain the hygiene environment around the factory. The
training must include GMP & HACCP principle during training session. Proper training
should be given by specialized person who have expertise on the topic. The training
sessions will ensure that employees are getting knowledge and proper evaluation must be
done to evaluate their performances. By training the employees,
References

Burton, L. (2019, April 16). Food Preservation Methods & Guidance. Retrieved June 03,
2020, from https://www.highspeedtraining.co.uk/hub/food-preservation-methods/

Care, D. (2015, February 20). Cleaning and Disinfection: Improving Food Safety and
Operational Efficiency in Food Processing. Retrieved June 03, 2020, from
https://www.foodsafetymagazine.com/signature-series/cleaning-and-disinfection-
improving-food-safety-and-operational-efficiency-in-food-processing/

Faul, R. (2019, July 26). Cleaning and Disinfection in Food Processing Operations.
Retrieved June 03, 2020, from
https://rethafaulconsulting.co.za/blogs/news/cleaning-and-disinfection-in-food-
processing-operations

MS 1514:2009 GOOD MANUFACTURING PRACTICE (GMP) FOR FOOD (First

edition)

Robbins, O. (2019, September 03). Food Storage and Preservation: Why it Matters and
How to Do it Properly. Retrieved June 03, 2020, from
https://foodrevolution.org/blog/food-storage-food-preservation/