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1. EXAMPLE OF A HACCP STUDY
This part describes how a HACCP study could be done. Its sole purpose is to provide guidance of doing a HACCP study for a basic margarine and spread product.
It should be noted that all information in this example (process layout, control measurements, critical limits, corrective actions, etc) are suggestions and in no way formal recommendations on how to run a margarine and spread plant.
1.1. HACCP Team
The first step is to assemble a HACCP team. This team should be multi-disciplinary to avoid a one-sided view on food safety : all knowledge on food safety hazards and potential solutions should be combined in this team.
HACCP Team (example) :
- production manager
- quality manager
- maintenance manager
- product development manager
1.2. Description of the Product
In principle, one study must be made for each product or a group of products having the same safety characteristics.
The example is a typical product for the industry :
- 80% fat, water, emulsifier, salt, citric acid, flavouring, and vitamins.
- The product is filled in a tub, the tubs are put into a secondary packaging on pallets.
- Shelf life of the product is 3 months, when stored at ambient temperatures.
- Microbiological assessment was done according Chapter B and product formulation was found to be stable.
1.3. Intended Use
The product can be used for spreading and cooking or frying by all consumer groups (children, adults, and elderly people).
Note : products containing a low fat content usually are unsuited for frying. This should be taken into account when doing the HACCP study.
1.4. Flow Diagram
This company prepares a stock solution of salt. This solution is then added to the aqueous phase. Otherwise, the process flow is analogous to the general process flow of chapter B. After production, the plant is cleaned (typically once a week).
1.5. Hazards and Control Measures for each Step
The HACCP team has identified following Hazards (short list for this example only) :
Physical
- glass (windows, lights)
- knives (used to open bags)
Chemical
- pesticides (raw materials)
- cleaning agentsMicro biological
- no pathogen hazard
The hazards associated with a certain process step are detailed in the table on p 19., columns 1-3. In this example, only the hazards mentioned above are dealt with.
1.6. Identification CCP's
See table on p. 25. The answers to the questions of the decision tree (Control measures in place/Is the step reducing the Hazard/Could contamination occur/Will a subsequent step reduce the Hazard) are given in the subsequent 4 small columns.
1.7. Establishment Critical Limits
If a step has been determined as critical for a certain associated hazard, the critical limits can be found in column 5 of the table.
These limits define the target level and tolerance of a specific parameter related to the CCP. Whenever this parameter is within the defined range, the CCP is well controlled.
1.8. Establish a Monitoring System
Monitoring : scheduled measurement or observation at a CCP of the compliance with the target level(s) and specified tolerance set down for each control measure.
The monitoring system describes the methods by which management is able to confirm that all CCPs are operating within specifications.
1.9. Establish Corrective Actions
Specifications of the actions to be taken when monitoring results show that a CCP has deviated from its specified tolerance.
See column 5 of the table.
1.10. Establish Verifications Procedures
Verification that the HACCP procedures are working properly : verification that the implementation of the HACCP study is properly done.
Apart from verification of the procedures, the HACCP study must be reviewed as well. The HACCP study should be reviewed on a regular basis since changes in product formulation, product processing, factory layout,etc could have an influence on the CCPs and consequently, on the corresponding procedures.
The HACCP team decided to verify the HACCP procedures in the following way :
- regular verifications whether instructions and procedures are followed.
- evaluation of the monitoring system regularly
- review of the HACCP study regularly
1.11. Record Keeping and Documentation
As it is important to be able to demonstrate that the HACCP principles have been correctly applied, accurate and complete records must be kept of all HACCP activities.
Examples of those records are :
- quality of raw materials
- processing, cleaning and disinfection records
- deviation files
- verification & review data
جدولش رو میتونید از سایت زیر دریافت کنید :
http://www.imace.org/margarine/appendices.htm