Implementation of HACCP to water treatment plant

Steps of Implementation of HACCP:

1. Assemble HACCP team

2. Describe product

3. Identify intended use

4. Construct process flow and plant schematic

5. On site verification of flow and schematic

6. Identify hazards (Principle #1)

7. Apply HACCP decision tree to determine CCP’s (Principle #2)

8. Establish critical limits (Principle #3)

9. Establish monitoring procedures (Principle #4)

10. Establish deviation procedures (Principle #5)

11. Establish verification procedures (Principle #6)

12. Establish record keeping/documentation for principles 1 - 6 (Principle #7)

Process flow diagram:

Distilled
turbine RO2
water

Mineral
Storage tank RO1
dosing

Filter
chlorination polisher
passing

Activated Sand Ozone Final

carbon purifier generator storage tank
HACCP plan and HACCP chart:

hazards Preventive CCP parameters/ Monitoring Corrective actions

measures limits procedure

Chemical: organic Define and Frequent chemical Protection of

matter, nutrients and determine analysis fecal source water or
fertilizer(N and protection zone, index bacteria, alternate of it
P),pesticide and eliminate the specific pathogens
fertilizer entrance of and turbidity
Microbiological: domestic and
Algae growth agriculture waste
,crustacean, water
Protozoa ,Eutrification
Chemical: Optimizing dose and Chlorine dose Determination of -Use of ozone
Over dose ,formation contact time of between 15- residual chorine at -use of
of THMs disinfectant 2.5ppm trace filter out let chloramines
level of residual
chorine at filter
outlet
Microbiological: Optimizing Turbidity less than Determination of -change in the
Crustacea ,protozoa, coagulant, 1.5NTUat turbidity and PH type and dose of
Oocysts and diatoma coagulant-aid dose sedimentation coagulant, mixing
Chemical: and mixing condition tank out let condition and PH
Poor flock formation
and removal of
inorganic substance
Filter clogging and Regular back Turbidity less than Determination of Modification or
filter defect washing and 0.4NTU at filter turbidity change of filter
cleaning, enhance out let bed
prior units works

Microbiological: Determine optimum On- line Free chorine -change the

Continuance and dose and contact monitoring residual 0.4- dosage of
propagation of time 0.6mg/l disinfectant or
pathogens change the
disinfectant

Chemical: production Frequent analysis THMs less than -Use of pre-

of odor ,Taste ,THMs 100ug/l chlorination and
and over dose of other disinfectants
chloride -optimize other
units prior to
disinfection
Hazards:

 Physical hazards

◦ Dislodged pipe tuber cell ,dirt ,sand

 Chemical hazards

◦ Industrial discharge

◦ Cleaning fluid

◦ pesticides

 Microbial hazards

◦ Bacteria, protozoa ,parasites and viruses

Verification procedure:

 Regular review of plant performance and equipment

 Routine plant operation checklists

 Calibration checks on measuring equipment

 Spot checks of water quality from treated water downstream of plant

Conclusion:

 HACCP, as a process control oriented management system, can therefore

help water authorities to coordinate the functions of their various water
quality management systems to provide assurance safe product.
 Poultry processing plant
Introduction:
➢ Meat and poultry products are sensitive to microorganism contamination by bacteria,
viruses and parasites.
➢ After becoming contaminated, meat and poultry provide an excellent environment for
growth of bacteria
➢ . Bacterial contamination and growth is a problem because it may result in food borne
illness.
➢ To improve product safety, the meat and poultry industries are adopting a process control
system known as “hazard analysis critical control point,” (HACCP).
➢ HACCP is a system of extensive evaluation and control over an entire food production
process for the sole purpose of reducing potential food-related health risks to consumers.
➢ HACCP is a program for the entire company; therefore, a team of individuals from
different areas of production and processing should be involved in developing the
HACCP plan.
➢ The team must include individuals with specific expertise
o such as live production,
o grow-out, processing,
o quality control,
o sanitation,
o microbiology,
o plant engineering,
o Research and development.
➢ This should make it easier to identify the hazards associated with each product.
➢ A HACCP coordinator should be chosen to work with the HACCP team and company
management to develop, implement and manage the HACCP plan.

HACCP’s Seven Principles:

1. Identify hazard
2. Identify critical control points
3. Establish critical limits
4. Establish corrective actions
5. Establish monitoring procedures
6. Establish verification procedures
7. Establish record keeping procedures
Process flow diagram:

Live Bird Receiving No ccp

Live Bird Holding No ccp

Unloading No ccp

Hanging No ccp

Slaughtering/Bleeding No ccp

Scalding No ccp

Defeathering
No ccp

Head and Feet removal

No ccp

Evisceration
No ccp

Grading No ccp

Packaging No ccp

Label
No ccp

Chill/Freeze Yes

Storage
No ccp

Vehicle
No ccp
HACCP Plan for Poultry Processing Plant:

Steps CCP Hazard (source) Preventive measure Monitoring

Poultry from certified Flock sourcing

Chicks history CCP 1 Disease carriers.
sources.

Feed from certified Feed sampling

Product
sources
Feed and contamination due to
CCP 2
storage pathogens and
And produced under
medication misuse.
certified conditions.

Water and Pathogens in potable Clean supply and Water sampling

CCP 2
storage water. protected storage.

Shedding of Testing for cleaning and

Catching and Application of feed and
CCP 2 pathogens through disinfection, visible inspection
transport water withdrawal
stress.

Water and product sampling,

Scalding and Cross contamination Sufficient water supply,
CCP 2 testing for cleaning and
plucking during the process. cleaning and disinfection.
disinfection

Cross contamination Product sampling testing for

Cleaning and disinfection
Evisceration Ccp2 through equipment cleaning and disinfection
during processing
and gut breakage.

Cross Sufficient water supply, Water and product sampling,

chilling Ccp2 contamination,(water cleaning and disinfection testing for cleaning and
and air) of evaporators. disinfection.

Product sampling testing for

Cross contamination Cleaning and disinfection
Cutting Ccp2 cleaning and disinfection.
(water and air borne) of cutting equipment.

Contaminated Visual check, proper

Packaging Ccp1
packaging material storage
Corrective Action:

• The cause of the deviation is identified and eliminated

• The CCP will be under control after the corrective action is taken

• Measures to prevent recurrence are established.

• No product that is injurious to health or otherwise adulterated as a result of the deviation

enters commerce.

Documentation:

1. A written hazard analysis, including all supporting documentation

2. A flow chart describing the steps of each process and product

3. The Written HACCP Plan Including:

✓ Decision making documents associated with the selection and development of

CCP’s and critical limits

✓ Documents supporting monitoring and verification procedures selected

✓ Records documenting the monitoring of CCP’s and their critical limits

5. Records documenting corrective actions.

6. Documents identifying verification procedures and the results collected from procedures

Verification procedure:

➢ Routine check of all HACCP plans and records.

➢ ∙ Routine check of monitoring procedures and equipment.
➢ ∙ Random microbiological sampling of all product contact surfaces, as well as a portion of
the product.
➢ ∙ Official evaluation of product.
➢ ∙ Review of all critical limit deviations and product handling.
DAIRY PROCESSING PLANT
Process flow diagram:

Recieving Raw Milk Booster Pump

Pasteurization Holding tube

Silo ≤4 HTST 72°C for (heated by
15 sec heater)

Pre-heating 60-
Homogenization Diversion valve Packaging
63°C

Standarization Pass
Seperator cooling
3.5% out valve

STEPS FOR PROCESSING:

Receiving:

Milk is a perishable commodity and spoils very easily. Its low acidity and high nutrient content
make it the perfect breeding ground for bacteria, including those which cause food poisoning
(pathogens). The price paid for milk is usually dependent upon the milk-fat content, and this may
be determined either at the collection stage or at the dairy using a piece of equipment known as a
butyrometer. Additionally the specific gravity can be measured using a hydrometer. This can
also be used as an aid to detect adulteration.
Silo:

Whole milk, once approved for use, is pumped into storage silos where it undergoes
pasteurization, homogenization, separation and further processing.

Pre-heating:

Preheating is done to facilitate the process.

Separator:

The fat fraction separates from the skim milk when milk is allowed to stand for 30 to 40 minutes.
This is known a `creaming'. The creaming process can be used to remove fat from milk in a more
concentrated form

Standardization:

The process of standardization involves standardizing fat contents. This is done for the fine
adjustment of fat contents in milk, according to which there should be 3.5% fat in whole milk.

Homogenization:

The milk is homogenized to reduce the size of the remaining milk fat particles
and thus prevent layer of cream from separating from milk. For this purpose milk is pumped at
high pressure. It ensures that the milk fat will be evenly distributed.

Pasteurization:

Then milk is is piped into a pasteurizer to kill any bacteria. The common is the high-temperature,
short-time (HTST) process in which the milk is heated as it flows through the pasteurizer
continuously. Whole milk, skim milk, and standardized milk must be heated to 161° F (72° C)
for 15 seconds. A temperature sensor at the end of the pipe diverts the milk back to the inlet for
reprocessing if the temperature has fallen below the required standard.

Cooling:

The milk is then quickly cooled to avoid harming its taste. Pasteurization does not destroy all of
the micro-organisms; therefore the milk has to be cooled rapidly to prevent the growth of
surviving bacteria.

Packaging:

Now the milk is ready to be packaged for delivery to the stores. The milk travels through pipes to
the automatic packaging machines that fills and seals the milk into paper cartons or plastic jugs.
As the containers move through the assembly line, a date is printed on each of them to show how
long the milk will stay fresh.
HACCP plan:

The following seven principles outline the basics of a HACCP program. These principles,
properly applied to a dairy plant, will result in minimizing the potential of a food borne disease
outbreak:

▪ Assess the hazards in a dairy plant.

▪ Determine critical control points (CCPs).
▪ Implement procedures to monitor CCPs and record data.
▪ Institute corrective action.

▪ Establish record keeping systems to document the HACCP plan.

Hazard chart:

Process step Potential hazard CCP

Receiving Antibiotic Yes

residues, microbes

Silo Microbial Yes

Pasteurization Microbial Yes

Corrective actions:
▪ Proper Inspection of milk at reception for acidity , pH , antibiotics in compliance to
standards.
▪ Maintain storage temperature at ≤4°C to ensure that milk is safely stored for further
processing.
▪ Time and temp. Combination should be well maintained.
▪ Valve should be checked every 3 months and repair if necessary.
Monitoring procedure:

 Acidometer is used to check for acidity of milk

 Methylene blue reduction, standard plate count, coliform plate count, purity plate culture,
gram staining are performed to check microbes level in pasteurized milk

 To determine antibiotics level chromatography mass spectrometry thin layer

chromatography are used.

Step Monitoring Procedure

At Receiving ➢ Ethanol test

➢ Acidity
➢ Colony count method (for bacteria)
➢ Strip test (for antibiotics)
➢ Bacterial activity

Documentation:

▪ Document for milk coming from the farm

▪ To keep the record of incoming milk’s pH acidity etc.
▪ Document for standardization
▪ To keep data of fat level at which each batch of milk is maintained.
▪ Document for Pasteurization
▪ To keep data of time-temp relationship in order to maintain a controlled
pasteurization process.
▪ Level of microbial load before and after it.