Name: Tharushi Dharmajeewa

Registration number: 20AGF2209

Subject: Food Quality Management
Individual Assignment 01
i
 Golden Roof
Turmeric Powder

Golden Goodness in Every Spoon-

ii
Contents
HACCP Team (step 1)............................................................................... 1
Product Description (step 2)....................................................................2
Intended Use (step 3)...............................................................................2
Plant Layout and Movement of Product and Personnel..........................3
Process Flow Diagram (step 4).................................................................4
(step 5).....................................................................................................4
Detail of working at each step.................................................................5
Record of Hazard Analysis (step 6)...........................................................8
(step 7, 8, 9, 10, 11, 12).........................................................................11
CCP 1: Drying.......................................................................................11
CCP 2: Grinding...................................................................................11
Appendix;...............................................................................................12
CCP Decision Tree................................................................................12
Risk assessment table.........................................................................13

iii
HACCP Team (step 1)
Title in HACCP Position in the
Name and Surname Skill
Team Organization
[Link]. in Food
Quality Assurance Science, Training in
Team Leader [Link]
Manager GMP and HACCP/
Codex
Purchasing Training of GMP
Member [Link]
Manager and HACCP/ Codex
Production Training of GMP
Member [Link]
Manager and HACCP/ Codex
Training of GMP
Member [Link] Training Manager
and HACCP/ Codex
Quality Control Training of GMP
Member [Link]
Supervisor and HACCP/ Codex
Maintenance Training of GMP
Member [Link]
Supervisor and HACCP/ Codex
[Link] Training of GMP
Member Grinding Operator
a and HACCP/ Codex
Packaging Training of GMP
Member [Link]
Supervisor and HACCP/ Codex
Sorting and Training of GMP
Member [Link]
Inspection Lead and HACCP/ Codex
Drying Process Training of GMP
Member [Link]
Operator and HACCP/ Codex
Ph.D. Food
HACCP System Technology and
Expert Training of GMP,
[Link] Consultant
(External HACCP, ISO22000,
expert) FSSC22000, BRC-
Food, IFS, SQF2000

Approved By:_Mr.[Link] Approval Date:…2024.07.06……

Effective Date:…..2024.07.06…..

1
Product Description (step 2)
Product Name Turmeric Powder
Dried turmeric fingers (rhizomes of Curcuma longa
Composition/Ingredient
plant)
Origin of Material Sri Lanka
Turmeric powder with no microbial contamination
(Salmonella, E. coli), no aflatoxins, free from
Product Characteristic
pesticide residues, no foreign objects (stones, dirt),
and no metal fragments
Method of Preservation
Controlled drying temperature and time
(Production)
Primary Packaging Food-grade plastic containers, vacuum-sealed bags
Other Packaging (For
Cardboard boxes, wooden pallets
transportation)
Cool, dry place (below 25°C), away from direct
Storage Condition
sunlight
Method of Distribution Sealed containers, temperature-controlled transport
and Transportation if necessary
Shelf Life at the Defined
12-24 months
Condition
Recommendation on Store in a cool, dry place. Not suitable for consumers
Labeling allergic to turmeric or related plants
Method of Preparation Ready to use as a culinary spice, dietary supplement,
for Consumption or traditional medicine

Intended Use (step 3)

Target Customer General Customer

2
Plant Layout and Movement of Product and
Personnel

PRPs (Prerequisite Programs)

1. Cleaning and Sanitation
To ensure the production of high-quality turmeric powder, rigorous cleaning and
sanitation procedures are essential. These measures prevent contamination and
maintain a hygienic processing environment.

 Facilities and Equipment Cleaning:

 Daily Cleaning: Clean all processing equipment and surfaces with food-
safe detergents and sanitizers at the end of each production day.

3
  Deep Cleaning: Conduct deep cleaning of all equipment and facilities
weekly, ensuring the removal of any residues or buildup.
 Documentation: Maintain a cleaning log to record dates, times, and
procedures used for cleaning and sanitation.

 Employee Training:
 Training Program: Provide comprehensive training on cleaning and
sanitation practices to all employees.
 Personal Hygiene: Emphasize the importance of personal hygiene,
including regular handwashing and the use of protective clothing.

 Verification:
 Swab Testing: Conduct regular swab tests on equipment and surfaces to
verify the effectiveness of cleaning procedures.
 Audit: Perform internal audits to ensure compliance with cleaning and
sanitation protocols.

2. Personal Hygiene
Maintaining high standards of personal hygiene among employees is crucial to
prevent contamination and ensure the safety of the turmeric powder.

 Hand Hygiene:
 Handwashing Stations: Install handwashing stations with soap and
disposable towels at key points within the facility.
 Hand Sanitizers: Provide hand sanitizers at entrances and exits of
processing areas.

 Protective Clothing:
 Uniforms: Require employees to wear clean uniforms, hairnets, and
gloves.

4
  Footwear: Ensure employees wear appropriate footwear that is cleaned
and sanitized regularly.

 Health Monitoring:
 Health Checks: Conduct regular health checks for employees to prevent
anyone with infectious diseases from handling the turmeric powder.
 Sick Leave Policy: Implement a strict sick leave policy to ensure that ill
employees do not come into contact with food products.

 Training and Education:

 Continuous Training: Provide ongoing training on personal hygiene and
its importance in food safety.
 Signage: Display clear signage throughout the facility to remind
employees of hygiene practices.

3. Pest Control
An effective pest control program is necessary to prevent contamination and
maintain the integrity of the turmeric powder.

 Pest Control Plan:

 Regular Inspections: Conduct routine inspections of the facility to
identify and address any signs of pest activity.
 Pest Control Service: Partner with a professional pest control service to
implement and maintain effective pest management strategies.

 Preventive Measures:
 Sealing Entrances: Ensure all entrances, windows, and other potential
entry points are sealed to prevent pest access.

5
  Storage Practices: Store raw materials and finished products in pest-
proof containers and areas.

 Monitoring and Documentation:

 Pest Traps: Place pest traps in strategic locations and monitor them
regularly.
 Records: Keep detailed records of pest control activities, including
inspections, treatments, and findings.

 Corrective Actions:
 Immediate Response: Implement immediate corrective actions when
pest activity is detected, including cleaning, sealing, and treatment.
 Follow-Up Inspections: Conduct follow-up inspections to ensure the
effectiveness of corrective actions.

Process Flow Diagram (step 4)

6
(step 5)
Verified by: _____ _____

([Link])

HACCP Team Leader

Date:____ 2024.07.06_____

7
Detail of working at each step
Step 1: Raw Material Receiving and Inspection (Low Risk Area)

 Details: Turmeric fingers are delivered by suppliers.

 Process Activities:
o Inspect for physical damage, mold, extraneous matter, and signs of
pests.
o Check temperature to ensure proper storage conditions during
transport.
o Collect samples for microbiological and aflatoxin testing by a
qualified laboratory.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Receiving bins, inspection tables, thermometers.
 Product Recycle/Rework Loops: Rejected materials returned to supplier.
 Segregation: Separate area for receiving to minimize contamination risks.
 Flow Conditions: Orderly, materials kept off the floor.
 Storage Conditions: Cool, dry, well-ventilated area.

Step 2: Pre-cleaning and Sorting (Low Risk Area)

 Details: Foreign material is removed.

 Process Activities:
o Remove stones, dirt, etc. manually or with mechanical separators.
o Sort turmeric fingers by size and quality.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Sorting tables, conveyors, mechanical separators.
 Product Recycle/Rework Loops: None.
 Segregation: Same area as receiving if adequately designed.
 Flow Conditions: Orderly, materials kept off the floor.
 Storage Conditions: Same as receiving.

Step 3: Washing (Medium Risk Area)

 Details: Turmeric fingers are washed with potable water.

 Process Activities:
o Wash with potable water to remove residual dirt and debris.
o Monitor water quality for microbiological contamination.
 Temperature/Time Profile: Ambient temperature water.
 Equipment: Wash tanks, sprayers, water filtration system.

8
  Product Recycle/Rework Loops: None.
 Segregation: Separate area from low-risk areas to minimize contamination.
 Flow Conditions: Controlled water flow, materials kept off the floor.
 Storage Conditions: Not applicable (continuous process).

Step 4: Drying (High Care Area - CCP 1)

 Details: Turmeric fingers are dried using controlled hot air dryers.
 Process Activities:
o Dry using hot air dryers with controlled temperature and time.
o Continuously monitor and record drying temperature.
 Temperature/Time Profile: 35°C minimum (This is considered a safe
minimum to avoid microbial growth while drying.) to 60°C maximum
(Higher temperatures can degrade curcumin, the active compound in
turmeric.) for a specified time(6-12 hours).
 Equipment: Hot air dryers, temperature monitors, data loggers.
 Product Recycle/Rework Loops: Product may be reworked if drying is
insufficient but not burnt.
 Segregation: Dedicated drying area with restricted access.
 Flow Conditions: Controlled airflow, materials kept off the floor.
 Storage Conditions: Not applicable (continuous process).

Step 5: Grinding (High Care Area - CCP 2)

 Details: Dried turmeric is ground into a fine powder.

 Process Activities:
o Grind using sanitized grinding equipment.
o Pass the powder through metal detectors.
o Visually inspect the ground powder.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Grinding mills, metal detectors, inspection tables.
 Product Recycle/Rework Loops: None for contaminated product.
Insufficiently ground powder may be reworked.
 Segregation: Dedicated grinding area with restricted access.
 Flow Conditions: Controlled airflow, materials kept off the floor.
 Storage Conditions: Not applicable (continuous process).

Step 6: Sifting (Medium Risk Area)

 Details: Turmeric powder is passed through sieves to achieve a uniform

particle size.
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  Process Activities:
o Pass the powder through sieves to achieve the desired particle size.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Sieves, sifting machines.
 Product Recycle/Rework Loops: Oversized particles may be reground.
 Segregation: Separate area from high-care zones to minimize
recontamination.
 Flow Conditions: Controlled airflow, materials kept off the floor.
 Storage Conditions: Not applicable (continuous process).

Step 7: Packaging (Low Risk Area)

 Details: The powder is filled into pre-sterilized food-grade containers.

 Process Activities:
o Fill the powder into pre-sterilized food-grade containers.
o Operate packaging lines under controlled sanitary conditions.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Filling machines, packaging lines.
 Product Recycle/Rework Loops: None.
 Segregation: Clean and controlled environment.
 Flow Conditions: Orderly, materials kept off the floor.
 Storage Conditions: Not applicable (continuous process).

Step 8: Labeling and Storage (Low Risk Area)

 Details: Finished products are labeled and stored.

 Process Activities:
o Apply labels with product information, manufacturing date, and
expiry date.
o Store finished products in a cool, dry, and well-ventilated warehouse.
 Temperature/Time Profile: Ambient temperature.
 Equipment: Labeling machines, forklifts.
 Product Recycle/Rework Loops: None.
 Segregation: Designated storage area.
 Flow Conditions: Orderly, materials kept off the floor.
 Storage Conditions: Cool, dry, and well-ventilated warehouse.

Distribution: Finished products are transported in clean and enclosed containers to

prevent contamination.

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 Record of Hazard Analysis (step 6)
Decision tree

Significanc
Likelihood
to Occur

Severity
Cause or Control Subsequent
Step Hazard CCP

e
Source Measure Q1 Q2 Q3 Q4 step
?
Source
Contaminated
turmeric from
raw materials,
reputable
Biological improper L M Mi Y N Y N No
suppliers with
storage at
GAP
supplier
certifications
1. Raw Source
Material turmeric from
Receiving Improper reputable
& pesticide use suppliers with
Chemical L H Mi Y N N/A N/A No
Inspection during GAP
cultivation certifications
and pesticide
residue testing
Implement
Contaminated visual
Physical L L Mi Y N Y N No
raw materials inspection
procedures
Maintain
Contaminated
proper
equipment,
sanitation
Biological improper L M Mi Y Y N Y No
SOPs for
worker
workers and
hygiene
equipment
2. Pre-
N/
cleaning Chemical N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
& Sorting
Implement a
thorough
Improper sorting process
Physical L L Mi Y Y N N No
sorting to remove
unwanted
materials
Use clean,
potable water -
Contaminated
Maintain
water,
proper
Biological improper M M Ma Y Y N Y No
sanitation
worker
SOPs for
hygiene
workers and
3.
equipment
Washing
Implement
Inadequate
proper rinsing
Chemical rinsing after L M Mi Y Y N Y No
procedures
cleaning
after cleaning
Inefficient Implement
Physical L L Mi Y Y N N No
sorting visual

11
 inspection
process
during washing
Maintain
controlled
Insufficient drying
drying temperature CCP
Biological H H Cr Y Y N Y
temperature and time to 1
or time inhibit
microbial
growth
Implement
4. Drying controlled
drying with
Excessive
appropriate
Chemical heat or light M H Ma Y Y N Y No
temperature
exposure
and airflow to
minimize heat
exposure
N/
Physical N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
N/
Biological N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
N/
Chemical N/A N/A N/A N/A N/A N/A N/A N/A N/A
5. A
Grinding Use metal
Grinding detectors to
CCP
Physical equipment M H Cr identify and Y Y N Y
2
wear and tear remove any
foreign objects
N/
Biological N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
N/
Chemical N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
6. Sifting Maintain sifting
Inefficient equipment and
sifting mesh size to
Physical M L Ma Y Y N N No
process or achieve
mesh size desired
separation
7. Use
Packagin Damaged appropriate
g packaging packaging
Biological allowing L M Mi materials that Y Y N N No
moisture prevent
ingress moisture
ingress
N/
Chemical N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
Physical Damaged L L Mi Use Y Y N N No
packaging or appropriate
improper packaging
handling materials and
proper
handling

12
 procedures
N/
Biological N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
N/
Chemical N/A N/A N/A N/A N/A N/A N/A N/A N/A
A
8. Improper Implement
Labeling storage proper storage
& Storage conditions, procedures
Physical damaged L L Mi (e.g., pest Y Y N N No
labels control) and
allowing entry use tamper-
of debris evident labels

(step 7, 8, 9, 10, 11, 12)

CCP 1: Drying
13
 Monitoring Verification
Hazar Cont Critical What Where Corrective
Step When to Activity
d rol Limit to to How to Action
Measur Who What/ Record
Meas Measur Measure
e Who
ure e
Dryin
35°C Throug
g Temperat
Micro minimum hout Adjust Supervi
temp Tem ure Drying
Dryin bial to 60°C the Continu Operat drying sor of
eratu perat monitor, tempera
g growt maximu drying ously or parameter the
re ure data ture log
h m for 6- proces s section
and logger
12 hours s
time

Validation Method (worst case): Simulate a scenario where drying temperature deviates slightly above or below the
critical limits (e.g., 33°C or 62°C) for a short duration. Microbiologically test the dried product under these conditions to
determine if microbial growth increases significantly.

CCP 2: Grinding
Monitoring Verification
Correcti
ve
Critical Where When
Step Hazard Control What to How to Action Activity
Limit to to
Measur Measur Who (What to What/ Record
Meas Measur
e e Do) Who
ure e

Segrega
te and
Physica
No After rework Supervi
l Metal Presenc After Metal
Grindin metal Metal grindin Oper or sor of
contami detecti e of grindi detectio
g detecte detector g each ator discard the
nants on metal ng n log
d batch contami section
(metal)
nated
product
Validation Method (worst case): Use the smallest metal piece the detector is supposed to identify and introduce it into
the grinding process at different points. This simulates a scenario where a small contaminant might escape detection.
Verify the metal detector consistently identifies these "worst-case" scenarios.
Frequency: During equipment installation and annually thereafter.

14
Appendix;
CCP Decision Tree

15
16
Risk assessment table

17