HACCP PLAN FOR APPLE JAM

Abstract
Apple jam is a gelled product made by boiling crushed apples with sugar and water.
Production of such a ready-to-eat food which is usually not refrigerated requires that all
food safety risks are eliminated. The use of the HACCP system has thus been applied as
food safety tool. These both ensure production of safe products and compliance with
basic regulations on food hygiene. The major sources of contamination, and the possible
pathogens and their toxins such as patulin form molds, Zygosaccharomyces rouxii, and
Toruluspora delbrueckii must be analyzed, and effective preventive measures
implemented.

Introduction
In general, it is accepted that jam is produced by taking mashed or chopped fruit pulp and
boiling it with sugar and water. It is also a widely accepted notion that jams are from the
pulp and juice of one fruit, rather than a combination of several fruits. The traditional
understanding of jam was that of a self-preserved cooked mixture of fruit and sugar. The
degree of preservation related to the final water activity of the product but there are other
factors affecting spoilage. These include soluble solid content, pH and titratable acidity,
as well as other unknown intrinsic indices related to the fruit used (Broomfield, 2001).
Commonly when the mixture reaches 105oC, the acid and pectin in the fruit react with the
sugar forming the gel which sets on cooling.

Apple jam is made of chopped apple fruit and apple purée and sugar. The use of apple is
advantageous because apple is on of the few non-citrus fruits known to have a high level
of natural pectin, thus the production can proceed without addition of commercial pectin.
Its acid levels are however low, but can be supplemented by natural screened lime juice.
The hazard analysis and critical control point (HACCP) system has over the years
become one of a reliable way to ensure safety at all levels in the food chain. Thus its
implementation in the production of a ready-to-eat product such as apple jam will be
most appropriate.

Term of reference
This HACCP study covers food safety hazard analysis, CCP determination, preventive,
control and corrective actions. Cleaning and sanitation operations (hygiene of production,
sanitation of production and non-production areas) are covered by Good Hygiene
Practice as a separate part of a HACCP plan to be applied at any step of production
processes where needed. The same is applied for raw materials reception, storage and for
labeling and packaging, which are done according to respective procedures. These are not
fully covered by the HACCP study, only concise notes were made where important.

HACCP Principles and Steps

HACCP is an analytical tool that enables a food entity to implement and maintain a
system for ensuring food safety. It generally involves assessment of all steps in the
particular manufacturing process, while identifying those steps that have a major effect
on the safety of the food (Burrow, 2001). The identification of the eventual critical
control points (CCP) along with monitoring and control parameters is then the results of
the analysis and culminates in the creation of the safety system. The HACCP system is
based on a universally recognized set of seven principles that are used to design a safety
plan for the food. These principles are:

1. Conduct hazard analysis

2. Determine CCP

3. Establish critical limits

4. Establish monitoring procedures

5. Establish corrective action procedures

6. Establish verification procedures

7. Establish record-keeping and documentation procedures

VI. Process description:

Sorting and washing
The apples are purchased from producers proving a certificate, decision on production
authorization or import of raw materials, or quality management certificate. The apples
are at reception transported to the storerooms or cold stores immediately after the
reception, where they are stored until distribution to further processing. Storerooms
should be clean, dry, cool and with good airing. Temperature and humidity in storerooms
are daily monitored. When defects are discovered during a control, the raw materials
must not be used and are discarded. At distribution a visual control of a raw material is
done, as well as a check of expiration date or minimal shelf-life date. When defects are
discovered, the raw materials are controlled in laboratory for sensory, microbiological,
and physicochemical properties. If the raw materials fulfill the conditions, they may be
used for processing – otherwise they must be discarded. When opening a storage tank
with raw material, care must be taken not to contaminate a content by a lid or mechanical
impurities.

For effective washing of fruits, 200 ppm of chlorine can be used in water. pH and
temperature should be maintained, to prevent fruits from getting damaged or bruised.
Dump and spray washers can be used in industries.

Peeling and coring

Fruits can be hand peeled or mechanically peeled. Then the flesh is automatedly cored by
machinery blades.

Cutting and sieving

Cutting is done to break apples down into smaller part so that the apples are cooked
thoroughly during the heating step.
The defined amounts of raw materials are sieved when needed or suitable before batching into a
vacuum jacketed steam vessel to make them homogenous. Sieved raw materials are gathered in a
mixing vessel.

Batching and heating

Raw materials are transported from a mixing vessel to a vacuum vessel using vacuum.

The inlet of water steam is shut open. The content of a vacuum vessel is heated to 85°C for
approx. 30 min to prevent enzymatic reactions and homogenize jam ingredients, what is
controlled in laboratory and data are recorded. Total soluble solids should be at least 22% at the
end of this stage.