HACCP Plan for Mango Juice Production
HACCP Plan for Mango Juice Production
Group No.3
Ingredients:
- Fresh Mango Pulp
- Water
- Sugar
- Citric Acid
- Ascorbic Acid (Vitamin C)
Key Characteristics:
Shelf Life:
6 months (under recommended storage conditions), 3 days refrigerated after opening.
Storage Recommendations:
Store in a cool, dry place away from direct sunlight.
Refrigerate after opening and consume within 3 days.
Allergen Information:
May contain traces of mango allergens (latex-fruit syndrome).
Raw Materials Used:
• Mangoes (varieties: Sindhri, Chaunsa)
• Filtered Water
• Refined Sugar
• Food-grade Citric and Ascorbic Acids
Packaging:
• PET or Glass Bottles
• Heat-sealed aluminum caps
• Labeling with nutritional and safety information
Intended Use:
Ready-to-drink beverage for public, consumed as a refreshing, hydrating fruit juice.
Target Consumers:
Children, adults, health-conscious individuals.
Distribution Market:
Domestic (Pakistan), with export potential
Relevant Regulations/Standards:
• Codex Alimentarius (CAC/RCP 1-1969, Rev. 4)
• Pakistan Standards (PS: Mango Juice 4527:2018)
• ISO 22000:2018 (Food Safety Management)
• FDA 21 CFR Part 120 (Juice HACCP)
Potential Hazards & Contamination Sources
Hazard Type Specific Source of Critical Limit / Likely CCP?
Hazards Hazard Control Point
Procedure:
Labelling Instructions:
• Product Name: “Fresh Mango Juice”
• Ingredients List: Mango pulp, water, sugar, citric acid, ascorbic acid (Vitamin C),
sodium benzoate (optional)
• Allergen Warning: “May contain traces of mango allergens (latex-fruit syndrome risk)”
• Regulatory Compliance: “Manufactured under ISO 22000, PS-4527, and Codex HACCP
guidelines”
PRE-REQUISITE NO. 4
CONSTRUCT FLOW DIAGRAM
Flow Diagram:
Pulp Extraction
Filtration
Pasteurization (CCP 2)
Cooling (CCP 3)
Storage
Distribution
PRE-REQUISITE NO. 5
ON-SITE VERIFICATION CHECKLIST
Step Process Matches Observation Correctiv Verified By Date
No. Step Flow s/ e Action
Diagram Deviations Needed
?
(Yes/No)
1 Receiving Yes – None
Mangoes
2 Sorting & No Additional Add rinse
Washing manual rinse step to
not on diagram
diagram
3 Peeling & Yes – None
Destoning
4 Pulp Yes – None
Extraction
5 Filtration Yes Filter mesh Add note
size varies – to flow
needs diagram
notation
6 Pasteurizati Yes – Confirm
on CCP in
HACCP
plan
7 Cooling Yes – None
8 Filling & No Hand Add QC
Sealing sampling check in
point not flow
indicated diagram
9 Labeling Yes – None
10 Storage Yes – None
11 Distribution Yes – None
Final Notes
Signature: ____________________________
PRINCIPLE NO. 1
HACCP HAZARD ANALYSIS
&
CONTROL MEASURES
Process Step Potential Hazard Hazard Analysis Control
Hazards Type (Likelihood/Severity) Measures
Receiving Pesticide Chemical, Medium/High Supplier
Mangoes residues; Biological, approval;
Pathogens on Physical Pesticide
skin (Salmonella, testing; Visual
E. coli); Stones, inspection and
dirt washing
Sorting & Contaminated Biological, Medium/High Use potable
Washing wash water; Physical water;
Damaged fruit; Periodic water
Foreign objects change;
Manual
sorting
Peeling & Contaminated Physical, Medium/High Equipment
Destoning equipment; Biological maintenance;
Metal shavings; Sanitation
Improper SOPs; Metal
handling detection if
applicable
Pulp Equipment Biological High Cleaning &
Extraction contamination; sanitation;
Microbial Time-
growth; Cross- temperature
contamination controls
Filtration Filter media Biological, Low/Medium Filter
contamination; Physical sanitation;
Incomplete Regular
removal of inspection
particles
Pasteurization Survival of Biological High (Critical) Critical
(CCP1) pathogens (e.g., Control Point
Salmonella, (CCP1);
Listeria); Time/temp
Insufficient control;
heating Temperature
records;
Equipment
calibration
Cooling Post-process Biological Medium/High Rapid cooling;
contamination; Hygienic
Microbial environment;
growth if Equipment
delayed sanitation
Filling & Recontamination Biological, High (Critical) Critical
Sealing (CCP2) during filling; Physical Control Point
Seal integrity (CCP2);
failure Hygienic
filling zone;
Seal
inspection;
Staff hygiene
Labeling Mislabeling (e.g., Chemical, Low/Medium Label
allergens); Physical verification;
Adhesive Approved
contamination materials
Storage Temperature Biological Medium Cold storage
abuse; Pest monitoring;
infestation Pest control
program
Distribution Temperature Biological, Medium Cold chain
excursions; Physical monitoring;
Damaged Visual
packaging inspection
PRINCIPLE NO. 2
CCP DETERMINATION FOR
MANGO JUICE PRODUCTION
Process Step: Receiving
Hazards Considered:
Biological (Salmonella, E. coli), Chemical (Pesticide residues), Physical
(stones, stems, leaves)
Yes
Yes
Yes
No
No Not a CCP
Process Step: Pulping
Hazards Considered:
Physical (metal fragments), Biological (equipment contamination)
Yes
No
No Not a CCP
Process Step: Formulation & Mixing
Hazards Considered:
Biological (cross-contamination), Chemical (overdosing additives)
Yes
No
No Not a CCP
Process Step: Pasteurization
Hazards Considered:
Biological (Salmonella, E. coli, Listeria)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No Not a CCP
Process Step: Labeling & Packaging
Hazards Considered:
Chemical (ink migration), Physical (sharp edges)
Yes
Yes
No
No Not a CCP
Process Step: Storage & Distribution
Hazards Considered:
Biological (temperature abuse), Chemical (package migration)
Yes
No
No Not a CCP
Q1 Q2 Q3 Q4 CCP HACCP Team
Process Step (Y/N) Comments
and Hazard
Washing and Yes – Yes – Yes – Yes – Yes CCP: Ensure
Sorting: Mangoes may Washing Damaged Stones proper
Microbial carry dirt, needed to fruits can or washing with
contamination, microbes, or remove harbor debris clean water
pesticides, pesticide surface pathogens. can be and sorting to
physical residues. contaminants present. remove
hazards . damaged fruit
and foreign
objects.
Pulping/Extract Yes – Yes – No – Not a No No Control
ion: Improper Equipment CCP but through GMP;
Contamination handling can cleanliness is needs good not a CCP.
from equipment introduce critical. manufacturi
or poor hygiene bacteria. ng practices
(GMP).
Pasteurization: Yes – Heat Yes – Yes – Yes – Yes CCP:
Pathogens like needed to kill Pasteurizatio Undercookin Monitor Pasteurize at
E. coli, pathogens. n is effective. g poses temper 82-85°C for
Salmonella risks. ature 15 sec.
and Continuous
time. temperature
monitoring
required.
Cooling: Risk of Yes – Warm Yes – Cooling Yes – Delays Yes Yes CCP: Cool to
bacterial juice can prevents are <5°C within 2
growth if not foster growth. hazardous. hours post-
rapid bacteria. pasteurizatio
n.
Packaging: Yes – Yes – Yes – Yes Yes CCP: Use
Post-processing Packaging Hygiene Improper sanitized
contamination material can during filling handling can containers.
introduce is critical. lead to Ensure clean
microbes. contaminati environment
on. and
equipment
during
packaging.
Storage and Yes – Yes – Needs No – No No Control via
Transport: Improper temperature Monitoring cold chain
Spoilage, storage can control. system maintenance;
temperature spoil juice. required. not a CCP if
abuse monitoring is
reliable.
PRINCIPLE NO. 3
CRITICAL CONTROL LIMITS
(CCLS) FOR CCPS IN MANGO JUICE
PRODUCTION
Process Step Hazard & Control CCP Target Critical Sources
Source/Cause Measure No. Value Limit
Post-process CCP: Cooling Sample bottle Rapid re- • Review cooling records
contamination CL: ≤5°C checked with cooling, retest • Equipment observation
within 2 thermometer product or • Microbial sampling
hours after cooling discard if not • Audit cooling process
compliant. compliance
Seal failure leading CCP: Filling & Visual/physical Stop line, • Review sealing records
to contamination Sealing check of seals reseal • Targeted seal inspection
CL: Air-tight every 30 containers, • Periodic external packaging
seal within 5 minutes sanitize audits
sec equipment.
The HACCP system verification ensures that the mango juice safety management procedures are
fully operational and effectively controlling all identified hazards. This involves routine
activities as well as periodic detailed reviews and testing, as outlined below: