Student Works: HACCP ANALYSIS CASE 3: CANNED SARDINE IN TOMATO SAUCE GROUP 1 whichever is considered normal. the thermal process also cooks the fish (sardines) and in some cases leads to bone softening. to render the food free from microorganisms capable of growing in the food at normal non-refrigerated conditions at which the food is likely to be held during distribution and storage". alone or in combination with other means of preservation. Packaging .. Product Name 2. Although this definition specifically refers to "nonrefrigerated" conditions and thereby excludes those semipreserved and pasteurized foods in which refrigerated storage is recommended.. While prevention of spoilage underlies all cannery operations. salt. tomato paste.30 mm thick. xanthan gum. The purpose of canning is to use heat. sufficient. Tinplate consists of a base plate of low-carbon mild steel. depending on the size of the cans which are to be manufactured and their intended application. Tin is applied to provide sacrificial protection 4. to kill or inactivate all microbial contaminants. which is fabricated into two and three piece cans of a wide variety of shapes and sizes.Product Chosen: “Ayam Brand” Canned Sardines in Tomato Sauce Product Description: 1. irrespective of their source. and to package the product in hermetically sealed containers so that it will be protected from recontamination. Base plate gauge varies. alone or in combination with other appropriate treatments. Preservation Method “Ayam Brand” Canned Sardines in Tomato Sauce Sardines fish. onto each surface of which is electrolytically deposited a layer of tin. this implies that commercially sterile canned foods will be free from microorganisms capable of growing at ambient or refrigeration temperatures. In relation to canned foods. Tinplate.15 and 0. the FAO/WHO Codex Alimentarius Commission (1983) defines commercial sterility as ". Canning is the preservation method. the condition achieved by application of heat. the product is said to be "commercially sterile". If a thermal process is sufficient to fulfill the criteria of safety and prevention of nonpathogenic spoilage under normal conditions of transport and storage. it is usually between 0. publications by the Department of Health and Social Security in the United Kingdom and the Standards Association of Australia do not exclude refrigerated foods. commercial sterility may then also encompass those foods which are intended to be stored at refrigeration temperatures. However. Composition / Raw Materials 3. palm oil. According to these less restrictive interpretations. (KL) Sdn. 7Elven. Method of storage 7.) in Malaysia to retailer such as Tesco. The labelling of the tin is directly printed on the surface. yet harmless. because they possess greater hardness than that of the pure metal. Distribute by the distributor (A.5. Intended Use of the steel base -the tin layer gradually dissolves and passes into the surrounding solution. Refrigerate after opening and best consumed within 3 days.25 mm. Alloys frequently lack the chemical resistance of pure aluminium. while the steel layer beneath remains protected. Store in a cool place and away from direct sunlight. alloys are well suited to the construction of cans. Aeon. The mechanical characteristics. lacking in pure aluminium yet required in the material for food cans. The dominant position of tin plate as the packaging material of choice for canned sardines has been challenged with the development of aluminium alloys. the thickness of the aluminium in fish cans normally ranges from 0. Method of distribution 6. Depending on the can size and the alloys used. However.21-0. Can be directly consumed after opening. It is customary to use sulphur resistant (SR) lacquer systems to prevent the formation of unsightly. blue/black tin and iron sulphides on the plate.Clouet & Co. Eating alone or serve with other food is ideal for this product. Double seaming in canning is to ensure hermetic seal to make product safer. Process flow diagram for canned sardine in tomato sauce Receiving Cutting . other supermarkets and convenient stores. Heating is encouraged as it is best to serve hot. Bhd. are obtained by the inclusion of small amounts of magnesium and manganese. Washing Can filling and pre-cooking Sauce filling Seaming Packaging Storage Dispatch . No No No No No No No - No No No . Reject the material if it is over the critical limits. E. V. fecal coliform and other microbes C: Histamine and Heavy metal Rationale for inclusion or exclusion as a Hazard Is this a Significant Hazard? Yes What measures can be applied to control this significant hazard? High temperature can reduce the number of microorganisms to minimum level. parahamolyticus. Is this raw material / packaging material a sensitive material? No Inclusion: Fresh fish always contains some microorganisms. Conduct analysis to check the present of histamine and heavy metal. Chemical-C. Inclusion: History shown that histamine and heavy metal always found in sardines No P: Foreign matter Tomato Paste B: None C: Pesticide Palm Oil P: None B: None C: None Inclusion: Sometimes foreign matter will stick with the fish.botulinum. - Yes Request certificate of Yes analysis from supplier.Hazard Analysis for Raw Materials and Packaging Raw Material / Packaging Material Sardine Potential Hazard (Biological-B. Physical-P) B: C. Exclusion: Strict control of suppliers under approved supplier program. coli 0157:H7. Washing can help to No remove the foreign matter. Inclusion: Metal fragment might be found as the can is made up of metal No - No Yes Washing No .Salt Xanthan Gum Can & Lid P: None B: None C: None P: None B: None C: None P: None B: Pathogens post contamination after retorting from defected can and lid C: Bishenol-ADiglycidyl P: metal fragment contamination Inclusion: Defect might be occur in can No No No No No No No Yes Visual inspection on the packaging No No No No No No No No Exclusion: Strict control of suppliers under approved supplier program. chemical or physical Rationale for inclusion or exclusion as a hazard Is this a What measure can be applied to Is this process a critical control point? (yes/no) Ensure the product received at between 1°C and 5°C YES significant control this significant hazard? hazard? (yes/no) Receiving BIOLOGICAL Microbiological growth Potential for pathogenic growth if product not kept under temperature control YES Sort/grade BIOLOGICAL CHEMICAL PHYSICAL Can be controlled by GMP implement Work procedures outline what staff are required to do NO Follow work procedures NO Washing BIOLOGICAL Microbiological growth Uses of non-potable water and/or unclean water No food safety hazard identified YES Ensure the uses of potable water by conduct the water testing YES Can filling and pre-cooking BIOLOGICAL CHEMICAL PHYSICAL NO Follow legislative requirements NO Sauce filling BIOLOGICAL No food safety hazard NO Follow legislative requirements NO .Hazard Analysis for Process steps Process step Potential Hazard state whether biological. every 2 hours) Additional visual and teardown examinations to be made at the start of production.CHEMICAL PHYSICAL Seaming BIOLOGICAL Microbiological growth identified Pathogen contaminant due YES to seam failure -Visual examination for double seam and other container defects at least every 30 minutes of continuous operation -Double seam teardown examination at intervals of sufficient frequency to ensure proper closure.g. machine adjustment or a prolonged shutdown -Regular supervisor checks of operator performance YES Packaging BIOLOGICAL No food safety hazards identified NO Follow legislative requirements NO . -Interval not to exceed 4 operating hours (e. immediately after seamer jam. and refer to temperature records) NO YES Store under refrigeration temperature 1°C to 5°C or seek alternative compliance for other temperatures YES .CHEMICAL PHYSICAL Storage BIOLOGICAL Microbiological growth Potential for pathogenic bacteria to grow if product not kept live at appropriate temperature Dispatch BIOLOGICAL Microbiological growth Hazard can be controlled by a work procedure NO Ensure the product is transported under appropriate temperature control (keep. Who Corrective Action Verification (What/How/ Frequency/ Who) Receiving Microbiological Zero Raw material Spec inspection form Every order Line QC Reject the raw inspector materials. inform supplier.2 ppm water testing other examination every container defects minutes of continuous operation . & Significant Process Step Hazards Critical Limits What How Monitoring Freq.HACCP Plan Summary CCP No. contact other suppliers Washing Microbiological Chlorine water Chlorine Chlorine At daily least Line QC Use inspector water Use clean and potable water Seaming Microbiological As per manufacturer’s specifications for particular can Double seam Visual and At least Line QC Stop production 30 inspector QC Manager Validation record Daily monitoring record Visual examination and filtered QC Manager Daily monitoring record QC Manager Raw record material Records not less than level of the residual 0. Adjust Double seam teardown At intervals not exceed to 4 of and defective seamer isolate stock teardown records Calibration maintenance records Corrective action report Internal report External report HACCP record review audit audit and and detain examination hours operating Storage Microbiological Refrigerated to 5⁰C Storage Check storage the Three times Line QC Throw away if QC Manager for daily inspector there microbial growth presents are Daily monitoring record Temperature record between -1⁰C temperature temperature monitoring .