07

QUI TRÌNH CHI TIẾT

DETAIL FLOWCHART
QUI TRÌNH CÁC THÔNG SỐ CHÍNH CP HOẠT ĐỘNG / GIỚI HẠN KIỂM SOÁT TIÊU CHUẨN
STAGE MAIN SPECIFICATIONS CCP RANGE OF OPERATION / CONTROLLING LIMIT STANDARD
(1) (2) (3) (4) (5)
Farming location In the safety areas (controlling by the Authorities) Safety areas
 Food safety / origin
Hatchery status Post larvae should be come from Legal controlled hatchery Controlled factory
declaration form checking
CCP Feeding status Feed mill come from Legal controlled feeding factory Controlled factory
For farming prawn
Farming status All farming records should be clear and easy trace back Available record.
(Trace-back form filling)
Conclusion PASSED: Receiving / NOT PASSED: Rejecting PASSED
 Food safety / origin form Catching area Natural catch shrimp: in FAO Area 71 (Pacific, Western Central) FAO area 71
CCP
For wild catch prawn Catching method With legal catching method Legal method
 Sampling methods for both Sampling every tank in truck – One tank 1-2 Piece. Total min 500g / sample Testing plan
FCP
internal / external testing Sampling in tank: should be pickup in top – bottom – and middle of tank At random.
Stage (1)  Chloramphenicol CCP Not used in hatchery – during farming. Not contained in any feeding / chemicals* ELISA (MRPL=0.3 PPB)
ANTIBIOTIC RESIDUE

 Nitrofuran Metabolites CCP Including Furazolidone; Furaltadone; Nitrofurantoin; Nitrifurazone (as above*) ELISA(MRPL=1.0 PPB)
SAMPLING  Flour-quinolone CCP Including Sarafloxacine; Ciprofloxacine; Enrofloxacine (as above*) ELISA (LOQ=1.0 PPB)
TESTING  Tetracycline CCP Not used in hatchery – during farming. Not contained in any feeding / chemicals Not detected
 Oxytetracycline CCP Not used in hatchery – during farming. Not contained in any feeding / chemicals Not detected
TRACEABILITY  Sulfonamide CCP Not used in hatchery – during farming. Not contained in any feeding / chemicals Not detected
(CCP)  Triphenyl-methane Dyes CCP
Sum of Malachite green/Leucomalachite green/ Gientian Violet & Leuco-gientian
ELISA (LOQ=0.5 PPB)
Violet
 Quinolone CCP Including Flumequine; Oxolinic acide (as above*) Not detected
 Triflurallin CCP Not used in hatchery – during farming. Not contaminated from agriculture areas ELISA (LOQ = 1.0 PPB)
 Ethoxyquine CCP May be contained in feeding. But should stop using enough time before harvesting. ELISA (MRPL=200 PPB)
 Agriculture drug residue FCP Not be contaminated during farming and not detected in shrimp. Not detected
 Heavy Metal residue FCP Not be contaminated during farming and not detected in shrimp. MRPL = 1 PPM
 Sulfite residue (SO2) FCP Not use Bisulfite as black tail prevention (For sea catch raw material) Under 10 ppm
 Bacterial testing FCP E.Coli, Salmonella, Vibrio Cholera,… Testing by Company laboratory Not Detected
Note: At this stage, only check E. Coli, Salmonella, V. Cholera.For the natural shrimp, there are just bacteria testing. Antibiotic may not do.
 Traceability Coding FCP Following Company Coding system (raw material lot / spices…)
Stage (2.1) Sampling At random (each tank each piece) General sample
RAW  Sensory checking with full
FCP
Cooking By micro-wave and/or boiling at 96oC up Boiling
guide-line Checking Eating and feeling by each person in testing room (at less 3) Personal recording
MATERIAL Conclusion Final conclusion by the leader basing on total idea
RECEIVING  Temperature checking by FCP
Temperature At random, core temperature under 10oC Target Under 5oC
Temp. warning 10oC to 15oC / passing if it have good sensory
hand thermometer.
FCP Temp. Rejecting Rejecting raw material lot if temp over acceptable limit Over than 15oC
Truck sanitation Inside truck should be checking by visual / Reporting SSOP 03 / GMP 01
 Truck sanitation checking FCP
Tank sanitation Tank with cover and sanitation checked by visual. Reporting SSOP 03 / GMP 01
 Waiting time RCP From Coming to receiving shorter than 06 hours Target 4 hours

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 Note: Non-conformity is separated and treated by the QC in line. Do not use Chlorine for the raw material lot which will use for EU market

(1) (2) (3) (4) (5)

FCP Standing Under 7oC. Controlled by hand thermometer Under 5oC
Stage (7)  Semi – product core RCP Running Under 10oC. Controlled by hand thermometer Under 7oC
FOOD  temperature
Soaking temperature FCP Under 8-12oC. Controlled by hand thermometer Under 10oC
ADDITIVE  Soaking time FCP From 0.5 to 18 hours depending on each items / customer specification. Not required
SOAKING
 Soaking tools RCP By soaking machine, speed Under 20cycles/minutes 18-20cycles/minutes
 Quality and size inspection FCP Once per batch – Controlled by Soaking QC Every 30 minutes
 Food additives and using FCP Phosphate Phosphate Blend 2-3% (optional) 2%
concentration FCP Non phos Non-phosphate – (2-3%) (optional) 2%
(depending on each FCP Salt NaCl - 99.9% - (1-2%) 1%
specification) RCP Others Depending on each specification.
Note: Not allow for using chemicals or ingredients without clean origin. Non-conformity is separated and treated by the QC in production line
RAW PRODUCTS PROCESSING (IN LOW-RISK AREA)
 Semi – product core FCP Standing Under 7oC. Controlled by hand thermometer Under 5oC
o
Stage (8.2) temperature RCP Running Under 10 C. Controlled by hand thermometer Under 7oC
 Processing practices RCP By visual checking on lighting table. Visual checking
FOREIGN  Brightness standard RCP Lighting brightness min 800 Lux (inside table)
MATTER  Semi-product keeping RCP With ice (flake ice and/or cold water)
Separating Every foreign matter and/or leg, vein, shell (from shrimp)
Flake ice
Company standard
 Checking practices FCP
CHECKING QC checking QC will check separated and decided counter measure.
Note: Non-conformity is separated and treated by the QC in line. Do not use Chlorine for the raw material lot which will use for EU market
FCP Draining Under 15oC. Controlled by hand thermometer Under 10oC
 Core temperature
RCP During washing Under 10oC. Controlled by hand thermometer Under 5oC
o
FCP  Core temp. Under 15 C. Controlled by hand thermometer every 30 min. Target <10oC
Stage (9.2)  Hand washing practice FCP  Chlorine 20-50 ppm. Starting 50 ppm / Ending washing 20 ppm > 10 ppm
FINAL Not applied for EU RCP  Water temp Using running water with temperature 10-15oC Target 10oC
market RCP  Water changing Every 30 times of washing (30 rings by counting set)
WASHING, RCP  Washing time 3-5 seconds (equivalence with 3 times of stirring by hand) Over 3 seconds
 Water quality RCP Following 98/83/EC and Japanese standard 98/83 EC
DRAINING  Draining time FCP From 5- 7 minutes depending on each size Max 10 minutes
 Quality and size inspection FCP Once per batch – Controlled by Soaking QC Every 30 minutes
Note: Not allow for using chemicals or ingredients without clean origin. Non-conformity is separated and treated by the QC in production line
BLANCHED PRODUCTS PROCESSING (IN LOW-RISK AREA)
 Core temperature of shrimp FCP Before blanching In range 10 oC - 20oC. Controlled by hand thermometer Under 15oC
Stage (8.1) (Verified every 30 minutes) FCP After blanching < 40oC. Checking immediately. Max 40oC
BLANCHING FCP Blancher temp. Min 95oC. Controlled by hand thermometer every 30 min. Company standard.
 Monitoring Criteria during FCP Biggest shrimp Not over biggest weight in size range (g per piece) (5D and/or 6D)
blanching (FCP stage) FCP Uniformity Not over 1.35 (by 10% biggest : 10% smallest) Depending on market
FCP Blanching time Level 01: 3-5s / Level 02: 5-7s/Level 03: 7-10s requirement.

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  Color checking FCP 20 UP Checking every lot during blanching basing on Salmon color rule Color 20 UP
Note:During cooking, None conformity lot / batch will be separated by QC and treated by QA who was in charge of cooked item controlling.

(1) (2) (3) (4) (5)

RCP Water temp. Under 10oC. Under spraying water Under 5oC
 Cooling controlling criteria
RCP Cooling time 3-5 seconds immediately outgoing from steamer. N/A
Stage (9.1) FCP Water temp. Under 5oC. Dipping shrimp in chilled water Under 5oC
RCP Dropping time 10 minutes. Controlling by countdown time N/A
COOLING  Chilling controlling criteria
FCP Core temp. Under 5oC. Checking by hand thermometer
CHILLING RCP Chilling time 10 minutes. Controlling by countdown time In range of 10 – 20m
 Changing chilling water RCP Single using chilled water (un recycle chilled water when once using)
Note: Non-conformity is separated and treated by the QC in line. Do not use Chlorine for the raw material lot which will use for EU market
COOKED PRODUCTS PROCESSING (IN HIGH-RISK AREA)
 Core temperature of shrimp FCP Before steaming In range 10 oC - 20oC. Controlled by hand thermometer Under 15oC
(Verified every 30 minutes) CCP After steaming >70oC (>72 oC in reality). Checking immediately. Min 72oC
o
CCP Cooker temp. Min 82 C. Controlled by hand thermometer every 30 min.
 Monitoring Criteria during Company standard.
CCP Biggest shrimp Not over biggest weight in size range (g per piece)
cooking (CCP stage) (5D and/or 6D)
Stage (8.3) For Laitram Cooking
CCP Uniformity Not over 1.35 (by 10% biggest : 10% smallest)
Depending on market
CCP Steaming time See Minimum steaming time for each size (validation yearly)
machine. requirement.
LAYING ON CCP Black spot room o o
Min 95 C. In range of 95 C – 98 Co

CONVEYOR  Monitoring Criteria during CCP Cooker temp. Min 95oC. Controlled by hand thermometer every 30 min.
cooking (CCP stage) CCP Biggest shrimp Not over biggest weight in size range (g per piece)
Company standard.
STEAMING For Local Cooking CCP Steaming time See Minimum steaming time for each size (validation yearly)
machine. CCP Uniformity Not over 1.35 (by 10% biggest : 10% smallest)
 Laying on conveyor RCP Laying on conveyor piece by piece. Shrimp was not overlapping each other Company standard
 Positive air pressure FCP In range of 5-10 Pa. Checking every day by QC in steaming stage >5 Pascal
Note:During cooking, None conformity lot / batch will be separated by QC and treated by QA who was in charge of cooked item controlling.
RCP Water temp. Under 10oC. Under spraying water Under 5oC
 Cooling controlling criteria
RCP Cooling time 3-5 seconds immediately outgoing from steamer. N/A
Stage (9.3) FCP Water temp. Under 5oC. Dipping shrimp in chilled water Under 5oC
RCP Dropping time 10 minutes. Controlling by countdown time N/A
COOLING  Chilling controlling criteria
FCP Core temp. Under 5oC. Checking by hand thermometer
CHILLING RCP Chilling time 10 minutes. Controlling by countdown time In range of 10 – 20m
 Changing chilling water RCP Single using chilled water (un recycle chilled water when once using)
Note: Non-conformity is separated and treated by the QC in line. Do not use Chlorine for the raw material lot which will use for EU market
 Semi – product core FCP Standing Under 7oC. Controlled by hand thermometer Under 5oC
Stage (10) temperature RCP Running o
Under 10 C. Controlled by hand thermometer Under 7oC
ADDED  Processing practices RCP By hand under flowing water taps
 Semi-product keeping RCP With ice (flake ice and/or cold water) Flake ice
PROCESSING  Added forming FCP Skewered, Butterfly; Back-cut; Belly cut; …. Depending on each specification Company standard
(SKW, BTF…)  Skewer sanitation/ checking FCP Checking to remove mold, bad status skewers. Sanitation by Steaming or Chlorine Steaming
 Skewer origin FCP Come from approved supplier (see sub material receiving) Company standard
 Washing after peeling (if so) FCP Chlorine 20-50 ppm. Starting 50 ppm / Ending washing 20 ppm Free Chlorine >10 ppm
Not applied for EU market. FCP Changing water Changing every 30 rings (one basket = one ring) 30 rings or less
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 08
BẢNG PHÂN TÍCH MỐI NGUY
HAZARDS ANALYSIS WORKSHEET
Are anyPotentialFood-
safetyHazardsSignificant Is this step
? a Critical
Identifying potential
(YES/NO) Control
hazards introduced, What preventive measures
Processing Justifying decisions Point (CCP)
controlled

Occurrence
Can be applied to prevent

Conclusion
of hazard
steps For column 3 or Defect

Severity
Or enhanced The significant hazards?

Likely

Final
Analyst
At this step
Point
(DAP)?

(1) (2) (3) (4) (5) (6)

Chemical:
Stage (1) Antibiotic residue. Checking Raw material declaration
(Which was potential used in sheet for necessary safe information
SAMPLING; farming areas) Noxious antibiotic may be such as: hatchery, post larvae, Feed
TESTING;  Chloramphenicol (CAP) misused during farming by mill, Chemical… used during farming.
Yes
 Nitrofuran Metabolites High High Yes lacking of information and its Sampling and testing those residue
TRACEABILITY CCP 01
(AOZ, AMOZ) residue will be harmful for (2) for each lot of raw material by
(FOR FARMING  Fluoroquinolones consumer’s health. ELISA assay test kit for initial
(ENRO, CIPRO) screening. Any positive require a
PRAWN)  Oxytetracycline/Tetra confirmatory test using HPLC/MS/MS
cycline
Chemical:
Antibiotic residue.
(Which was not potential used
in farming areas) Checking Raw material declaration
 Nitrofuran Metabolites sheet for necessary safe information
(SEM, AHD) such as: hatchery, post larvae, Feed
Noxious antibiotic not have any
 Fluoroquinolones mill, Chemical… used during farming.
evidence and/or not using
(SARA) Yes
High High Yes during farming but its residue
 Quinolone Every shipment should be sampled CCP 01
will be harmful for consumer’s
(Flumequine, and tested as random at least 5
health.
Oxolinic Acid) sample and/or following Annex 5 –
 Triphenylmethane table II in BAP standard (Version No.
Dyes 04)
(Sum of MLG & LMLG
Sum of GV & LGV)
 Sulfonamide

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 Physical:None
(1) (2) (3) (4) (5) (6)
Biological:
Low Low No Controlled by GMP
Stage (8.2) Bacteria growth
Biological:
FOREIGN Low Low No Controlled by SSOP
Bacterial contamination
MATTER Chemical:
None
CHECKING Physical:
None
Biological:
Low Low No Controlled by GMP
Bacteria growth
Biological:
Stage (9.2) Bacterial contamination
Low Low No Controlled by SSOP
FINAL WASHING Chemical: Sodium Hypochlorite should not use for No
Misused antiseptic Low High Yes EU market and/or its concentration Controlled by GMP and SSOP. Defect Control
DRAINING may higher than standard. Point 02
Physical:
None
Biological:
Low Low No Controlled by GMP
Bacteria growth
Pathogenies bacteria may
Stage (8.3) survive after cooking, it may Controlling core temperature (>72oC)
Biological: Yes
LAYING DOWN Low High Yes damage the consumer’s health with 6D standard and adequate
Bacterial survived (CCP 03)
because it was ready-to-eat cooking time for each size.
ON CONVEYOR product
STEAMER Chemical:
None
Physical:
None
Biological:
Low Low No Controlled by GMP
Bacteria growth
Biological:
Stage (9.1) Low Low No Controlled by SSOP
Bacterial contamination
BLANCHING Chemical:
None
Physical:
None
Stage (9.1/3) Biological:
Low Low No Controlled by GMP
Bacteria growth
COOLING Biological:
Low Low No Controlled by SSOP
CHILLING Bacterial contamination
Chemical:
None

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