Overview
Individual report on a HACCP case study of food process
Value: 30%
Length: approx 2000 words
Due – Friday 23rd September by 11:59pm
Submission requirements
The assignment must be submitted as a single file, including appendix, by the
due date, uploaded to vUWS Turnitin. The report title should include your
surname and HACCP topic.
The uploaded report will be marked using the rubric in Turnitin. Please
review your feedback and comments in Turnitin (the comments cannot be
viewed in Grademark).
Please ask for advice if needed during the workshop on how to compile the
excel spreadsheets (HAW & HAT) into a single readable Word file, OR
compile files into single PDF file. Multiple files cannot be uploaded for
assessment.
The task
Each student will conduct a HACCP case study for a particular food
product.
Supporting information for the HACCP case study will be provided on
vUWS, including templates for Hazard Assessment Worksheets and HACCP
Audit Table, along with references for the relevant standards and
recommended readings.
Students will be guided through each section of this assignment during a
series of 2 x 3-hour workshops.
HACCP Audit Table
Firm Name: Product Name:
Firm Address: Product Description:
CCP
No
Ingredient or Process
Step
(from HAW)
Hazard
Type
B, C or P
CCP
(type of control
measure)
CCP Critical
limits
Monitoring What &
How
Monitoring
Frequency
Corrective
actions
Records
1
2
3
4
5
Add additional rows as needed for each CCP identified in the Hazard Assessment Worksheet.
Hazard Assessment Worksheet Date: 1st May 2018 (EXAMPLE)
Firm Name: Hawkesbury Milk Product Name: Pasteurised Milk
Firm Address: Bourke Street, Richmond NSW Product Description: Chilled pasteurised homogenised milk
Method of Distribution and Storage: 2L plastic bottles, packed into crates, distributed by refrigerated truck
Intended Use and Consumer: stored at <4oC, used within 15 days of manufacture,
for consumption by the general public
1234567RAW MATERIALSIdentify and describe Potential Hazard(s) Introduced, Controlled, or Enhanced at This StepAre the Potential Food Safety Hazards Significant? Justify Your Decision for Column 3What Preventive Control Measure(s) are applied to control these Hazards?Is this a Critical Control Point ?CCP NoRaw Milk
At deliveryBiological:
Raw milk may contain pathogenic bacteria: Bacillus cereus , Listeria monocytogenes, Yersinia enterocolitica, Salmonella spp, Escherichia coli O157:H7, Campylobacter jejuni and bacterial spores YesFood Poisoning,
Risk of milk spoilageTransport and delivery at <4° = CCP
Raw material specification: compliance with FSANZ 4.2.4 Primary Production Standard for Dairy – PRP
Supplier audits – PRPYes1Chemical:
AntibioticsYesDrug resistant bacteria becoming prevalent in society.
Failure of fermentation processes (eg yoghurt)Antibiotic testing at delivery = CCP
FSANZ 1.4.2 Maximum Residue Limits compliant – PRPYes2Physical:
stones, dirt, dust, glass, metal fragments, animal hairNoChoking, physical injury, separation at later stageClean milking equipment – PRP
Supplier audits – PRPNoAllergen:
Milk proteinsYesHuman allergy – MILK proteinLabelling at later stage – PRPNoPlastic Milk bottles
At deliveryBiological:
bacterial contaminationNoFood poisoning, milk spoilage
Low risk if produced to specRaw material specification – Supplier audits – PRP
Packaging stored under hygienic conditionsNoChemical:
Residues of plastic monomersNoPlastic monomers can cause intoxication, low risk if MRL stds adhered to. Raw material specification – Supplier audits – PRP (FSANZ 1.4.3 Articles and Materials in Contact with Food)NoPhysical:
Fragments of packaging getting into productNoChoking hazard – low risk if packaging intact and produced to specificationRaw material specification – Supplier audits – PRP No
1234567PROCESS STEPS
List each step from FPCIdentify and describe Potential Hazard(s) Introduced, Controlled, or Enhanced at This StepAre the Potential Food Safety Hazards Significant?Justify Your Decision for Column 3What Preventive Measure(s) are applied to control these Hazards?Is this a Critical Control Point?CCP NoStorage of raw milk Biological:
bacterial contamination,
bacterial grow during storageYesFood Poisoning if not delivered chilledMilk stored at < 4°C = CCP
Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ 3.2 Food safety programs compliant
Lab tests for bacterial count and pH – PRP
Thermometer calibration – PRP
Yes3Chemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ 1.3.3 Processing aids compliance – PRP NoPhysical
Metal from equipment,
Disintegrating rubber seals NoChoking risk,
Particle separator at later stage Equipment maintenance – PRPNoClarification of raw milkBiological:
somatic cells, bacterial sporesNoFood poisoning, heat process at later stageEquipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ 3.2 Food safety programs compliantNoChemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ 1.3.3 Processing aids compliant -PRPNoPhysical:
stones, dirt, dust, glass, metal fragments in raw milk NoChoking, physical injuryCentrifugal processing to remove foreign particles- PRP
Removal of sludge from holding space – PRP NoStandardisation mixing tank
Biological:
bacterial contamination of tankNoFood poisoning,
heat process at later stage Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ 3.2 compliantNoChemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ FSC 1.3.3 Processing aids compliant – PRPNoPhysical:
foreign particle contamination from pumps, pipes and tankNoChoking, physical injury
Low risk if equipment maintainedEquipment maintenance – PRPNoHomogenisationBiological:
bacterial contamination of homogeniserNoFood poisoning, heat process at later stage Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ 3.2 compliant
No
Chemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ FSC 1.3.3 Processing aids compliant – PRPNoPhysical:
foreign particle contamination from homogeniser NoChoking, physical injury
Low risk if equipment maintained,
Check at later stageEquipment maintenance – PRPNoPasteurisationBiological:
Failure of pasteurisation may result in food poisoning bacteria risk: Salmonella spp, Escherichia coli O157:H7 Listeria monocytogenes, Yersinia enterocolitica. Heat resistant pathogens : Mycobacterium tuberculosis and Coxiella burnetii YesFood poisoning if not adequately pasteurisedMilk heated at 72°C for 15 secs = CCP
Flow Diversion valve (FDV) to reprocess inadequately heated milk
Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP, FSANZ 3.2 Food safety programs compliant
Thermometer calibration – PRP
Equipment maintenance – PRP
Yes4Chemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ FSC 1.3.3 Processing aids compliant – PRP
NoPhysical: foreign particle contamination from heat exchanger equipment and pumpsNoChoking, physical injury
Low risk if equipment maintained
Check at later stageEquipment maintenance – PRPNoChillingBiological:
Failure of chiller allow bacteria to grow bacterial contamination of chillerYesFood poisoning if not chilledMilk chilled to <4oC
Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ FSC 3.2 compliant
Thermometer calibration – PRP
Equipment maintenance – PRP
Yes5Chemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ FSC 1.3.3 Processing aids compliant – PRPNoPhysical:
foreign particle contamination from heat exchanger equipment and pumps
NoChoking, physical injury
Low risk if equipment maintainedEquipment maintenance – PRPNoFilling of Plastic bottles, with lid closure fittedBiological:
bacterial contamination of filling equipment
failure of closure causing leaksNoLow Food poisoning risk, maintained as chilled Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ 3.2 compliant
Equipment maintenance to ensure seal integrity is maintained in equipment – PRPNoChemical:
CIP cleaning chemicalsNoCleaning chemical & sanitiser contamination
Low Intoxication riskCIP cleaning protocol SoP – PRP
FSANZ FSC 1.3.3 Processing aids compliant – PRPNoPhysical:
foreign particle contamination from equipment or plastic bottlesYesChoking, physical injury magnetic metal detection of foreign particles Equipment maintenance – PRP
Supplier agreement for bottles – PRPYes6Chilled StorageBiological:
failure of chiller allow bacteria to grow bacterial contamination of chillerYesFood poisoning if not chilledMilk maintained at <4oC in cold storage
Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ FSC 3.2 compliantYes 7Chemical:
Nil for packed productNonilnilNoPhysical:
Nil for packed productNonilnilNoChilled DistributionBiological:
failure of chiller allow bacteria to grow bacterial contamination of chillerYesFood poisoning if not kept chilledMilk maintained at <4oC in refrigerated trucks
Equipment sanitised on regular basis to prevent bacteria contamination and growth – PRP
FSANZ FSC 3.2 compliantYes8Chemical:
Nil for packed productNonilnilNoPhysical:
Nil for packed productNonilnilNo
HACCP AUDIT TABLE (EXAMPLE)
Firm Name: Hawkesbury Milk Product Name: Pasteurised Milk
Firm Address: Bourke Street, Richmond NSW Product Description: Chilled pasteurised homogenised milk
CCPIngredient or Process Step (from HAW)Hazard Type
B, C or PCCP
(type of control measure)Critical limitsMonitoring What & HowMonitoring FrequencyCorrective actionsRecords1Raw Milk DeliveryBiologicalChilled Milk delivery Temp <4°CTemperature probe,
Direct measurement of milk while still in tankerEach tanker is tested at delivery, prior to unloading.If > 5.5°C redirect milk to alternate product (eg flavoured milk)
If > 7°C reject milk delivery
Investigate cause for high temperature and correctMilk temperature delivery records
Rejection records
Calibrations
2Raw Milk deliveryChemicalAntibiotic testingZero result for AntibioticsCharm ROSA (Rapid One Step Assay &
Charm MRL Beta-lactam/ Tetracycline
2 Minute Test for MilkEach tanker is tested at delivery, prior to unloading.If antibiotics detected using Charm rapid test, do follow-up test using the Delvo test to verify the presence of antibiotics
Reject milk delivery if antibiotics detected by both Charm and Delvo tests.
Investigate cause for antibiotics and correct (ensure farmer remove affected cows from milking herd)Milk delivery records
Charm test log
Delvo test Lab test records
Rejections3Raw milk storage BiologicalChilled Milk storage Temp <4°CTemperature probe,
Direct measurement of milk while in milk silosContinuous monitoring of milk silosIf > 5.5°C redirect milk to alternate product (eg flavoured milk)
If > 7°C dump milk
Identify cause for inadequate chilling in silo and correct problem
Temperature data logs for milk silos
Calibrations
Rejections4Pasteurisation of milkBiologicalPasteurisation Temp & time
72oC for 15 secondsTemperature probe at exit of pasteuriser, timing monitored by pump flow rate Continuous monitoring of exit temperature & pump flow rateIf < 72oC use FDV to return milk to balance tank for re-pasteurisation. Alarm to alert failure of pasteuriser.
If pump flow rate fast or fails. Alarm to alert failure of pasteuriser. Dump milk
Identify cause for failure of pasteurisation and correct problemTemperature data log of pasteuriser
Pump flow rate log
Calibrations
Rejections5 Chilling of pasteurised milkBiologicalChilling of milkTemp <4°CTemperature probe at exit of chiller after pasteurisation Continuous monitoring of chiller post pasteurisation If > 5.5°C redirect milk to alternate product (eg flavoured milk)
If > 7°C dump milk
Identify cause for inadequate chilling and correct problemTemperature data logs for chiller post pasteuriser
Calibrations
Rejections6Filling of milk into bottlesPhysicalDetection of metal particles in milkZero detection of metal particlesMetal DetectorContinuous monitoring If metal particles detected, reject and dump milk
Collect rejected samples and Identify cause for the presence of particles and correct source of problemData logs for checks, calibrations and rejections7Chilled storage of milkBiologicalCold storage of milkTemp <4°CTemperature probe in cold storeContinuous monitoring with alarm
Manual temperature check of cold store If > 5.5°C redirect milk to alternate product (eg flavoured milk)
If > 7°C dump milk
Identify cause for failure of cold storage and correct problemTemperature data logs
Calibrations
Rejections8Distribution of milkBiologicalChilled distribution of milkTemp <4°CTemperature probe in truckContinuous monitoring of truck with back to base alarm If > 5.5°C redirect milk to alternate product (eg flavoured milk)
If > 7°C dump milk
Identify cause for failure of chilling of truck and correct problemTemperature data logs
Calibrations
Rejections
