HACCP PLAN FOR INDUSTRIAL Abdul Rahman

MANUFACTURING OF
CHOCOLATE Tahir
ABDUL RRAHMAN TAHIR 1
ABDUL RRAHMAN TAHIR 2
HAACP

3
ABDUL RRAHMAN TAHIR
 Introduction
HACCP Benefits
Elements
H A CCP P la n I d e ntific a tion p a g e
A s s e mb le th e H A CCP Te a m
Intended Use
Flow Chart

OVERVIEW HACCP- 7 PRINCIPLES

HAZARD ANALYSIS
CONTROL MEASURE AND CRITICAL
CONTROL POINT
CCP DECISION TREE
CRITICAL LIMITS
MONITORING
CORRECTIVE ACTIONS
DOCUMENTATION ABDUL RRAHMAN TAHIR 4
 HACCP is
abbreviation of
Hazard Analysis
and Critical Control
Points

Identifies, evaluates
and controls
hazards which are
significant for food
safety
INTRODUCTION
ABDUL RRAHMAN TAHIR 5
 Maximize
product safety

Improved
management
responsibility

Improved process
control

Improved inspection
testing.

HACCP-BENEFITS Moving the industry

towards a quality
management system
ABDUL RRAHMAN TAHIR 6
 • A trained HACCP team
• Product description
• Intended use
The • Process flow diagrams
•
elements
Hazard analysis, determine and
establish Critical Control
ELEMENTS suggested Points and corrective actions
(HACCP Principle 1-4)
are as • CCP Monitoring (HACCP
Principle 5)
follows: • Verification process (HACCP
Principle 6)
• Record keeping (HACCP
Principle 7)

ABDUL RRAHMAN TAHIR 7

 Product Chocolate

Company
MAAN Lovebury
name

Company 03000445516
Contacts Abdulrahmantahir786@gmail.com

HACCP PLAN IDENTIFICATION

PAGE
ABDUL RRAHMAN TAHIR 8
 NAME POSITION

Asad Ullah Tahir HR Manager

ASSEMBLE Abdul Rahman Tahir Inspect receiving

THE HACCP Muhammad Waseem

Processing

TEAM Muhammad Usman Maintenance

Muhammad Junaid Sanitation

Ali Raza Quality control

Moin Quality Assurance

Kashif Rajab Ali Record keeping

ABDUL RRAHMAN TAHIR 9

MILK CHOCOLATE
Production starts with top quality cocoa
beans, cocoa beans are processed to produce
the cocoa mass, which contains 53% cocoa
and cocoa butter, the basis for all chocolate
products

Sugar is added to the condensed milk with

some of the cocoa mass, making a rich
creamy chocolate liquid, which is then
evaporated to make milk chocolate crumb

ABDUL RRAHMAN TAHIR 10

PACKAGING AND STORAGE
Chocolate packaged in Storage
Aluminum Cool and dry Place
Paper 70 F
Cardboard Humidity 55%
Hermetically sealed or wrapped for
ultimate convenience
The packaging is according to the
requirement of market

ABDUL RRAHMAN TAHIR 11

 Milk Chocolate
Dark Chocolate
Unsweetened Chocolate
White Chocolate
Chocolate Milkshakes
Chocolate Cakes

INTENDED USE
ABDUL RRAHMAN TAHIR 12
 Roasting the
Drying Cleaning and
Receiving Fermentation cocoa beans
6-7 % moist sorting
105 -120 C

Alkalization Conching
Winnowing Grinding Tempering
K2CO3 49-82 C

Storage
Molding Packaging
70 F

FLOW CHART
ABDUL RRAHMAN TAHIR 13
 HACCP- 7 PRINCIPLES

1 2 3 4 5 6 7

Conduct Determine Establish Establish Establish Establish Establish

Hazard The Critical Critical Corrective Verificatio Document
Critical Limits. Control Action. n ation.
Analysis. Point CCP
Control Procedure
Point CCP Monitorin s.
. g System.

ABDUL RRAHMAN TAHIR 14

 HAZARD ANALYSIS
PROCESSING PHYSICAL CHEMICAL BIOLOGICAL
STEPS HAZARD HAZARD HAZARD

1)RECEIVING Wood, chaff, plant pesticides, fertilizers Worms ,insects

materials

2)FERMENTATION Wood pieces Microbes

(Salmonella spp )
-
3)DRYING Dust , foreign mold
matters

4)SORTING AND Damage Hygiene

CLEANING ABDUL RRAHMAN TAHIR 15
PROCESSING PHYSICAL CHEMICAL BIOLOGICAL
STEPS HAZARD HAZARD HAZARD

5)ROASTING Microbial growth

due to insufficient
roasting

6)WINOWING Dust ,foreign Polluted air Microbes

matters in air contamination (contaminated air)
7)ALKALIZATION Chemicals Microbial
contamination
8)GRINDING Metals Chemicals from Microbial
Equipment contamination
9)CONCHING Metals Microbial
Contamination
ABDUL RRAHMAN TAHIR 16
PROCESSING PHYSICAL CHEMICAL BIOLOGICAL
STEPS HAZARD HAZARD HAZARD

10)TEMPERING Metal fragments Contamination

from poorly
maintained
Equipment

11)MOULDING Dust particles, plastic Uncleaned

materials Moulds

12)PACKING Foreign matter Labelling ink and

packaging
material
13)STORAGE Improper conditions

ABDUL RRAHMAN TAHIR 17

 CONTROL MEASURE AND CRITICAL
CONTROL POINT
PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL
POINT/CONTROL
POINT
RECEIVING P-sorting CP1
C-chemicals free
materials
B-proper building setting
FERMENTATION P-visual inspection CP2
B-proper maintenance of
fermentation tanks
DRYING P-visual inspection CP3
B-proper maintenance of
time and temperature ABDUL RRAHMAN TAHIR 18
PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL
POINT/CONTROL
POINT
SORTING AND CLEANING P-GMP’s B-Personal Hygiene CP4
ROASTING B-Roasting of cocoa beans in CCP1
stated period of time and
temperature
WINNOWING P,C,B-use of air filters CP5
ALKALIZATION C-Proper Amount Of CP6
Alkalizing Agent
B-sanitize the equipment
GRINDING P-visual inspection CP7
C-sanitize the equipment
B-sanitize the equipment
CONCHING P-Visual inspection CP8
B-proper maintenance of
ABDUL RRAHMAN TAHIR 19
equipment
PROCESSING STEPS CONTROL MEASURES CRITICAL CONTROL
POINT/CONTROL
POINT
TEMPERING P-visual inspection CP9
C-Sanitize the equipment

MOLDING P,B-Use of properly CP10

maintained molds
PACKAGING P-Use of metal detectors CCP2
C-Use of appropriate
packaging material and
labelling ink
STORAGE P-Maintain Temperature CP11
P-Proper handling

ABDUL RRAHMAN TAHIR 20

PROCESS BLOCK DIAGRAM
FOR CCP CCP

Cleaning Roasting the

Receiving Fermentation Drying
and sorting cocoa beans

Winnowing Alkalization Grinding Conching Tempering

Molding Packaging Storage

CCP ABDUL RRAHMAN TAHIR 21

 CCP DECISION TREE ROASTING
Question 1:Does Roasting involve a hazard of sufficient likelihood of occurrence and
severity to warrant its control?

yes Biological Hazard

Question 2:Does a control measure for the hazard exist at this step?

yes

Question 3:Is control at this step necessary to prevent, eliminate, or reduce the risk of
the hazard to consumers?

yes CCP Roasted at 105-120ºC ABDUL RRAHMAN TAHIR 22

 CCP DECISION TREE PACKAGING
Question 1:Does Packaging involve a hazard of sufficient likelihood of occurrence and
severity to warrant its control?

Physical and Chemical

yes
Hazard

Question 2:Does a control measure for the hazard exist at this step?

yes

Question 3:Is control at this step necessary to prevent, eliminate, or reduce the risk of
the hazard to consumers?

yes CCP Packaging in Aseptic condition.

ABDUL RRAHMAN TAHIR 23
CRITICAL LIMITS

CCP1:
Roasted in special ovens at temperatures between 105-120ºC. The
actual roasting time depends on whether the end use is for cocoa or chocolate
CCP2:
Wrapping of chocolate done at aseptic condition.

ABDUL RRAHMAN TAHIR 24

MONITORING
1)RECEIVING:
CHECK :Visual inspection of incoming goods
RECORD : Presence or absence of contamination
2)FERMENTATION
CHECK : Proper checking of fermentation tanks
RECORD : Presence or absence of contamination
3)CLEANING AND SORTING
CHECK : Proper personal Hygiene And GMP’s
RECORD : Presence or absence of contamination
ABDUL RRAHMAN TAHIR 25
 4)DRYING
CHECK :Drying temperature and time
RECORD : Temperature and time is noted.
5)ROASTING
CHECK : Proper temperature and time for roasting
RECORD : Temperature and time is noted
6)WINNOWING
CHECK : Personnel hygiene , sanitation of equipment and air filters
RECORD : Record any incident of poor personnel hygiene on
personnel record
7)ALKALIZATION
CHECK : Amount Of Chemicals and sanitation of chemicals
RECORD: Amount of Chemicals is noted
8)GRINDING
CHECK : Visual inspection
RECORD : Record any resulted maintenance ABDUL RRAHMAN TAHIR 26
 9)CONCHING
CHECK : Regular inspection of equipment
RECORD : record any resulted maintenance
10)TEMPERING
CHECK : Regular inspection of equipment
RECORD : record any resulted maintenance

11)MOULDING
CHECK: Proper maintenance of molds
RECORD : Molding check

12)PACKING
CHECK : Visual control And
RECORD : Packaging checks
13) STORAGE
CHECK : Temperature and storage Conditions
RECORD : Storage checks
ABDUL RRAHMAN TAHIR 27
CORRECTIVE ACTIONS
1)RECEIVING
Reject contaminated cocoa pods
2)FERMENTATION
Provide good condition to avoid microbial attack
3)DRYING
Dry the product to stated period
4) SORTING AND CLEANING
Maintain personnel hygiene and equipment sanitization
5)ROASTING
Roasted to stated time and temperature
6)WINNOWING
Provide good quality of air
ABDUL RRAHMAN TAHIR 28
7)Alkalization
Proper chemical check and proper maintenance of equipment
8)GRINDING
Proper maintenance of equipment

9)CONCHING
Proper maintenance of equipment and material

10)TEMPERING
Proper Cooling and heating

11)MOULDING
Product will be retained and reworked or discarded

12)PACKING 13) STORAGE

Maintain aseptic condition Temperature Control And Proper
and proper cleaning of packaging plant storage conditions
ABDUL RRAHMAN TAHIR 29
VERIFICATION PROCESS
Verification of HACCP plan after one month
 Checking for instrument calibration and the reviewing of records
Review of CCP records, critical limits, and microbial sampling and analysis
procedures
System check annually
verify monitoring process when system fails

30 ABDUL RRAHMAN TAHIR 30

 Critical control point records
Personnel hygiene records
Raw materials records
DOCUMENTATION Record any resulting maintenance record
Inspection of equipment's record
Time-temperature record

ABDUL RRAHMAN TAHIR 31

 Staff training purpose
Suppliers in the case of any disputes or
problems
DOCUMENTATION Customers confidence
Food safety inspection
Frequency of cleaning equipment

ABDUL RRAHMAN TAHIR 32

 HACCP is related To
Food Safety
Our product is
completely safe due to
HACCP
Complete HACCP of
Industrial Manufacturing
Of Chocolate
Learn how to make
HACCP Plan

CONCLUSION
ABDUL RRAHMAN TAHIR
33
REFERENCES
https://www.slideshare.net/Abdulrahmanmaan/chocolate-industry-
125627498?qid=8f13d8e6-ea8f-4dcb-a673-
e78f34ce3369&v=&b=&from_search=7
 https://www.slideshare.net/safeenapa/haccp-plan-in-chocolate
https://www.santabarbarachocolate.com/blog/cocoa-powder-
alkalization-method/
https://www.loeschpack.com/branches/chocolate-packaging.html

ABDUL RRAHMAN TAHIR 34

ABDUL RRAHMAN TAHIR 35