MINISTRY OF EDUCATION AND TRAINING NONG LAM UNIVERSITY – HO CHI MINH CITY FACULTY CHEMICAL ENGINEERING AND FOOD TECHNOLOGY Class DH18TP INSTANT GREEN TEA POWDER INSTANT DRINK December 2021 Ho Ch.
MINISTRY OF EDUCATION AND TRAINING NONG LAM UNIVERSITY – HO CHI MINH CITY FACULTY: CHEMICAL ENGINEERING AND FOOD TECHNOLOGY Class: DH18TP INSTANT GREEN TEA POWDER INSTANT DRINK GROUP - MEMBERS Nguyễn Thị Thanh Vân Hanna Võ Nguyễn Thục Trinh Rina Đỗ Hồng Ánh Mai Mia Nguyễn Thu Hiền Helen Đỗ Thị Yến Ly Pine Bùi Thiên Lộc Thomas Hồ Thanh Tuyền Jena Nguyễn Thị Kim Tuyền Kitten Trương Thị Thanh Xuân Xuan December 2021 - Ho Chi Minh city TABLE OF CONTENT TABLE OF CONTENT INTRODUCTION HACCP TEAM PRODUCT DESCRIPTION AND INTENDED USE FLOW DIAGRAM PLANT LAYOUT PROCESS STEP DESCRIPTION RISK ASSESSMENT AND CCP, OPRP DETERMINATION 12 HACCP PLAN 18 OPRPs PLAN 19 DISCUSSION AND CONCLUSION 21 Discussion: 21 Non-CCP hazards: 21 CCP hazards: 22 Non-OPRP hazards: 23 OPRP hazards: 23 Conclusion: 25 REFERENCES 25 INTRODUCTION HACCP is an abridgment of the Hazard Analysis Critical Control Point system, which is tantamount to food safety management Essentially, it is “a system which identifies, evaluates and controls hazards which are significant for food safety’’ It is a system that gives confidence that food safety is being controlled effectually The hazards that need to be analyzed and controlled are biological, chemical, and physical hazards from raw material production, procurement, and handling, to manufacturing, distribution, and consumption of the finished product or anything that could go wrong regarding product safety and implements controls subsequently to ensure that the product will not cause harm to the consumer OPRP as a control measure identified by the hazard analysis as necessary to control the likelihood of introducing food safety hazards and contamination or increase of food safety hazards in the product or the processing environment OPRP is definite action relating to the process, although not being critical for food safety, but they are essential in reducing the probability of specific hazards occurring Turning green tea leaves into instant green tea powder is a complicated process that included many stages of preparing as well as processing To achieve good products quality and food safety and hygiene Mainly hazards biological from E Coli bacteria, Salmonella, Coliform, etc and other physical hazards, chemistry, allergies need to be minimized to the maximum Research plans for the Hazard Analysis, Critical Control Point (HACCP), and OPRP systems for pre-processing and processing at instant green tea powder factories need to be discussed, researched, implemented, and focused, followed clearly to minimize the unfortunate threat to products quality HACCP TEAM No Name Position Responsibility Hanna Plant Manager HACCP team leader Helen QA Manager Committee Jena Production Manager Committee Kitten QC Manager Committee Mia Engineering Manager Committee Pine Packaging supervisor Committee Rina Raw materials reception manager Committee Thomas AG Supervisor Committee Xuan Warehouse operative Committee Skill/ Experiences BSc - Food Science MSc - MBA 10 years of experience GMP, HACCP, ISO certificate BSc - Food Sci & Tech GHP, HACCP training years QA experience BSc - Food engineering GHP, HACCP training years QA experience BSc – Chemistry GHP, HACCP training years QA experience BSc - Engineering GHP, HACCP training years QA experience BSc –Control Engineering and Automation GHP, HACCP years of experience BSc -Food Science HACCP certificate years of experience BSc - Food Sci & Tech GHP, HACCP training years QA experience BSc -Food Science GMP, HACCP, ISO certificate years of experience PRODUCT DESCRIPTION AND INTENDED USE Product name / Group product Instant green tea powder Composition -100% pure green tea leaf powder -No additives Important product characteristics - pH from 7-10 of end-product (e.g., pH, aw, - Not an allergen Allergen, etc.) - 60% polyphenols (19.98 ± 1.15 mg/100 g dry leaf weight) How the product is to be used - teaspoon powder with 200ml warm water (60 - 80℃), stir well to mix with sugar, milk to drink better - Make a face mask Packaging (net weight, etc.) - Packed with aluminum foil sachets in a paper box - Net weight: 40g (2g x 20 sachets) Shelf-life and storage condition - Shelf-life: years - Storage: Please store tea powder in a dry place at room temperature and keep away from direct sunlight Where the product will be sold - Supermarkets, markets - Retailer - E-commerce platform Labeling instructions Nutrition information, serving size, EXP, ingredients, manufacturing information, imported by the importer Special distribution control No physical damage, avoid placed with high temperature or humidity 10 Consumer group All ages except children under three years FLOW DIAGRAM Information: Tea powder is packed in aluminum foil sachets with a weight of 2g per sachet (20 sachets per box) The product contains 100% pure green tea leaf powder, does not have any allergen and is suitable for all ages except children under years old This product can be used to make soft drinks (1 teaspoon for 200ml warm water) and can be used as a mask (mixed with yogurt, honey in a 1:1 ratio) Nutrition information, serving size, EXP and ingredients are declared on label The storage condition: cool, dry place and avoid physical damage PLANT LAYOUT To avoid cross-contamination in food manufacture, the factory must be designed and organized in accordance with HACCP and must adhere to the one-way rule from input materials to final products As a result, the factory is divided each level of cleanliness into production and non-production areas I Production area Reception raw material (incoming materials and raw materials store): Raw products are in the proper conditions (avoid places with high temperature or humidity) and method so as to maintain quality and reduce loss of the material during storage + Incoming raw materials where the company imports raw materials including tea leaves, water, paper box, and aluminum foil sachet from distributors + Raw material storage room is used for storing, checking and classification the quality of raw materials, as well as preliminary processing before materials, go into processing Processing area The processing area plays an important role in the company in which raw materials (tea leaves) are directly variable into the final product (instant tea powder) Therefore, the area must be of high quality in order to obtain safe and high-quality products according to GMP and HACCP standards Packaging area Applying proper packaging methods and ensuring hygienic conditions will reduce the risk of contamination with hazards in the packaging process to a minimum After packaging, the products are checked once again to ensure there is no mistake on the outlook and no metal contamination in each product Packaging warehouse Packaging warehouse is used to store packing materials to avoid cross-contamination and to expand space for the packaging process Finished products warehouse Finished product warehouse is where the products are stored as well as get ready for export II Non-production area Lab It is used for microbiological testing in tea powder and other related matters, followed by the administration Freezing system This system helps to control and maintain the ideal temperature for freezing steps Water treatment system The purpose of a water treatment facility is to make water potable and palatable while also ensuring that there is a sufficient supply of water for the company's water needs Raw water is pumped, or flows, to a treatment facility Once there, the water is pretreated to remove debris such as leaves and silt Then, a sequence of treatment processes - including filtration and disinfection with chemicals or physical processes - eliminates disease-causing microorganisms Clean in Place system In food processing, insufficient cleaning can result in reduced efficiency, contamination in final product, and energy losses To optimize widely implemented clean-in-place (CIP) systems, it is critical to understand the influence of the interactions between surfaces, fouling, and chemical agents on the efficiency of the cleaning process (AvilaSierra, Zhang, & Fryer, 2019) This system helps to clean the interior surfaces of pipes, vessels, types of equipment, filters without major disassembly Waste storage Proper waste management is important to protect human health and the environment, so this area should be located in the farthest location to ensure hygiene and easily treat the waste when it goes out of the environment Employee canteen and relaxing area, packing area for employee's welfare and visitor parking area for the welcome PROCESS STEP DESCRIPTION # Processing steps/ Incoming Process step description materials Paper box Paper boxes are transported to food factory by trucks receiving After harvesting, it should be transported quickly to the processing factory Tea by trucks with specialized containers or by trucks carrying bags containing leaves receiving tea leaves Before being put into the warehouse, it must be carefully checked the quality assessment criteria Water receiving Water is received from a water factory and stored in large water tanks Aluminum Aluminum foil sachets are delivered from the supplier and stored in the foil sachet warehouse Leaves are washed to remove residue, sand on the surface of tea leaves The Washing water used to wash the tea leaves has a temperature of 25-30º C and drains Firstly, the tea particles need to be made into small particles to increase the surface area contact of tea particles to the solvent to extract more soluble Rolling/Grinding solid from the structure of the particles and not to impair the extraction yield Normally, the range of the particles size from around 100 micrometers to around 180 micrometers is optimal Drying: High-temperature drying is not desirable for water-soluble components of green tea contain very easily oxidizable components, Drying (Steaming) such as ascorbic acid and catechins Therefore, such drying methods as vacuum drying, freeze-drying, and spray drying are considered suitable 9 10 11 12 Steaming: The method comprises the following steps of pre-dissolving the tea raw materials such as tea leaves, tea stems, and tea residue, performing steam explosion under the pressure of 0.8 to 1.8MPa, keeping the pressure for 0.5 to times, collecting the steam explosion material, and performing purification, concentration and drying according to the state of a steam explosion system to produce the instant green tea powder Using the hot extraction, the size of particles should be maintained larger, usually more than 500 micrometers to 800 micrometers The type of solvent used for this step should be low cost, safe for human health, safe for the environment So now people more refer to use water or ethanol However, Extraction ethanol is much more expensive compared to water So, people tend to use hot water with a temperature from 70oC to 90oC to increase the extraction yield of the soluble solid from the materials The ratio between the dry matters (tea particles) to the solvent should be in the range of 1:2 to 1:10 mean portion in weight of the dry matters and portions in weight of the solvent until 10 portions in weight of the solvent Filtration At this step, the mixture of solid and liquid matters will be filtrated to remove extraneous objects or solid materials from the extraction step The main purpose of this step is to utilize some ways to recover or collect the volatile through the technique of condensation People use water vapor flow to move this volatile together with water vapor through another lower Aroma Stripping temperature area, with the absolute humidity if it moves to the lower temperature area, the condensation occurs When condensation occurs, water vapor will be condensed into the liquid form and the volatile will be dissolved in the solution This solution will be remixed with the input fluid before the freeze-drying step Using the osmotic evaporation (OE) process: The effect of the OE process on the content of phenolic compounds and antioxidant activity was evaluated The concentration process was carried out in a hollow fiber membrane contactor with an effective surface area of 0.54 m2 The tea extract was Concentration circulated through the shell side of the contactor, while a concentrated osmotic solution (CaCl2 M) was circulated inside the fibers It is possible to reach a tea concentration of 40% (w/w) in 5h, with a constant water flux and without losing the phenolic content and antioxidant potential in most teas During the freezing stage, the material is cooled below its triple point, the lowest temperature at which the solid, liquid, and gas phases of the material can coexist To facilitate faster and more efficient freezePre-Chilling drying, larger ice crystals are preferable To produce larger crystals, (Freezing) the product should be frozen slowly Temperature: -18OC Time: hours Method: Using a cryogenic freezer upstream of a spiral freezer 10 C: P: Sand, dust, insect fragments Rolling/Grinding - M H ✓ - HACCP OPRP HACCP ✓ OPRP ✓ ✓ HACCP OPRP HACCP OPRP HACCP OPRP HACCP ✓ OPRP Mi Cr Ma - - - - B: - - - - - P: Sand, dust - - Good implementation of GMP, SSOP Extraction will remove all impurities M A: Tea dust (food allergy in Use N95, N99 Respirators sensitized individuals) or air filter masks H Drying/Steaming B: Escherichia coli and Salmonella The organism’s heat sensitivity makes it possible to eliminate with LTHT treatment (low temperature and high temperature) M P: Iron particles To remove iron, magnets are often placed at the mouth of the dryer, belt, and color sorter to catch iron particles in different stages of the process M - - B: Salmonella, E coli, Cryptosporidium parvum, Coliform C: Epidallocatechin-3gallate, chlorine Clean water testing, water treatment operation, water analysis before extracting Control the concentration of substances to the minimum allowed M L H C: Chemical contamination To keep clean and, where can arise because of necessary after cleaning, to environmental disinfect, in an appropriate pollution, lubricants from tea manner, facilities, processing machinery, equipment, containers fumigant residues from the Use the right amount of fumigation of containers lubricant for machine maintenance A: Extraction Proper implementation of GMP Clean and maintain the machine regularly - ✓ A: - C: - - OPRP H M M - L L M L 13 Ma Ma Ma Mi Mi - - - - - - - ✓ - OPRP-3(P) - - - - - - ✓ - - - - - HACCP ✓ - - - - OPRP HACCP ✓ ✓ - - - - OPRP ✓ - - - - - HACCP ✓ - - - OPRP ✓ - - - - HACCP ✓ - - - OPRP ✓ - - - - - HACCP OPRP HACCP ✓ - - - - OPRP ✓ - - - - - HACCP ✓ - - - OPRP ✓ - - - - - - - P: Sand, Stones, … A: Filtration B: L monocytogenes - H M - M P: - - B: Microbial (Salmonella spp.) growth M M C: Abuse of artificial - Training staff to follow flavoring leads to exceeding strict guidelines the allowable threshold - Strengthen supervision in this stage - Do not abuse artificial flavorings - - H L - L - - Perform regular cleaning and maintenance of machines to avoid crosscontamination - Follow proper cleaning and sanitizing procedures A: 11 Concentration - B: E coli microorganisms, Clean the filter properly yeasts, molds Select filter core with a small size to filter microorganisms C: Chlorine, strange odors: Choose a good filter Poor quality charcoal filters material with high will absorb organic absorption capacity compounds less efficiently Replace the filter layers as prescribed (6 months/1 time) P: Insoluble residue, foreign Clean the filter regularly for matter Improperly cleaning normal filtration the filter A: - 10 Aroma Stripping GMPs: using water for extracting M L - - - Ma Ma Mi Mi - - Take great caution when modifying the temperature - Inform the factory manager to temporarily suspend production to establish on-site corrective actions H C: - Monitor cleaning and - Contaminants such as checking status at the lubricants from the machines beginning and end of shifts that are not hygienic every day - Training workers again about equipment hygiene knowledge H L Mi H L Mi - The leak of CaCl2 from the -Checking and maintaining fibers of the contactor in the stability of the osmotic evaporation contactor process L Mi 14 Mi HACCP ✓ - OPRP ✓ - - HACCP OPRP HACCP ✓ ✓ OPRP ✓ ✓ HACCP ✓ OPRP - - - - - ✓ - - 13 - - ✓ - - ✓ ✓ - HACCP ✓ - OPRP ✓ - - HACCP OPRP HACCP ✓ OPRP ✓ HACCP ✓ OPRP - - - - - - - - - - - - - - - - - - - - - ✓ - - - - HACCP OPRP HACCP OPRP HACCP ✓ - - - OPRP ✓ - - - - HACCP ✓ - - - ✓ - - - - - - - - 12 Pre – chilling (Freezing) (-18oC/2 hour) P: - - - - - A: - - - - - B: L -Perform regularly cleaning monocytogenes, Salmonella and maintenance of machines to avoid crosscontamination - Follow proper cleaning and sanitizing procedures - Humidity control is extremely important H C: Mycotoxin Source control: COA, AVL) Processing control Control GMP, especially GHP personal hygiene (personal cleanliness) M - - P: A: 13 Freeze Drying (-35oC/8 hours) - B: L - Perform regularly cleaning monocytogenes, Salmonella and maintenance of machines to avoid crosscontamination - Follow proper cleaning and sanitizing procedures - Humidity control is extremely important C: Chemical contamination lubricants from the machine P: - Dust form machines - Electrical problems lead to damage to machinery and affect product quality - Do regularly cleaning and checking of the machines to prevent leaking lubricants - Do regularly cleaning and maintenance of machines to avoid dust and soils - Follow proper cleaning and sanitizing schedules - Ensure sufficient power supply for machines M L - - - H M L L L M 15 Ma Mi Ma Mi Mi OPRP ✓ - - HACCP OPRP HACCP OPRP HACCP ✓ ✓ ✓ OPRP ✓ ✓ ✓ HACCP ✓ - OPRP ✓ - - HACCP OPRP HACCP OPRP HACCP ✓ ✓ - - OPRP ✓ ✓ ✓ ✓ ✓ HACCP ✓ - OPRP ✓ - - HACCP ✓ - - - - - - - - - - 13 OPRP-4(B) - - - - - CCP- (B) - - - - - - - - A: 14 Instant green tea powder B: Mold: Aspergillus ochraceous C: P: Impurities of metal samples A: 15 Packaging B: - C botulinum, E coli, Salmonella from workers, mold C: - P: Impurities (metal, jewelry) A: 16 Sealing by heat sealer B: Growth of microorganisms (mold) - Destroy by temperature control packing condition - - - L L - - Use a magnet suction machine/detector to remove pieces of metal H - - M - M L OPRP ✓ - - HACCP OPRP HACCP - - - - - - ✓ - OPRP ✓ HACCP OPRP HACCP ✓ ✓ ✓ - OPRP ✓ - - HACCP OPRP - - - - HACCP ✓ - OPRP ✓ ✓ ✓ ✓ - HACCP - - - - Mi OPRP HACCP ✓ - OPRP HACCP OPRP HACCP ✓ ✓ - - ✓ OPRP ✓ ✓ ✓ HACCP ✓ OPRP ✓ HACCP OPRP HACCP Mi Ma Mi - Controlled by GMP/GHP - Store the package in a dry place and check the package regularly - Check the quality of the packaging carefully before use - Regularly clean and check the heat-sealing machine - - L L - - H M Ma - Workers must follow the right operation; check and remove the incomplete sealed products - - - - - - - 17 - - - - - - - - - OPRP-5(B) - - - - - - - CCP-2 (B) - ✓ ✓ - - - - - - - - - - ✓ ✓ - - - - - - - - - - - - - Control the humidity of the air C: Chemical contamination Do regularly cleaning and lubricants from the machine checking of the machines to prevent leaking lubricants L P: Impurities (jewelry, sands, ) L A: - Controlled by GMP - L L - 16 Mi Mi - 17 Metal detector B: - - - - - C: - - - - - P: Metal fragments A: 18 Boxing/Labeling B: - Bacillus spp., Clostridium spp., Staphylococcus spp - Bacteria or mold C: P: A: - - Products are put through metal detectors to remove product packages containing metal - Periodically, check the metal detector by QC L - - - Controlled by GMP/GHP - Clean and maintain the machine regularly - Place the product in a dry place - H - M L - - - - - - S-Severity, O-Occurrence, Sig Hazard (Cr = Critical, Ma = Major, Mi = Minor) 17 Ma - Mi - OPRP HACCP OPRP HACCP OPRP HACCP ✓ ✓ - - OPRP ✓ ✓ ✓ HACCP OPRP - - HACCP ✓ OPRP HACCP OPRP HACCP OPRP HACCP OPRP - CCP-3 (P) - ✓ ✓ - - - - - - - - - ✓ ✓ ✓ ✓ - - - - - - OPRP-6(B) - - - - - HACCP PLAN CCP No CCP- (B) Significant hazards B: L monocytogene s, Salmonella Freeze Drying Control measures Critical limits (CL) - Perform regular cleaning and - CL: maintenance of machines to 35oC/9 avoid cross-contamination hours - Follow proper cleaning and sanitizing procedures (-35oC/8 hours) - Humidity control is extremely important - OL: 37oC/9 hours Monitoring Procedure: Corrective Action Verification Records (What/How/Frequency/Who) - What: Microbiological testing for machinery and equipment - How: Manage time, temperature, and humidity appropriately during the freeze-drying process Taking samples for microbiological testing after each batch of frozen tea concentrate - Frequency: Drying conditions must be checked regularly Equipment and tools must be cleaned before and after use All of them should be recorded on the checklist for easy tracking Process: - Isolate the batch of frozen tea concentrate contaminated with microorganisms Microbiological testing after each batch of frozen tea concentrate A-001 - Check the machine's operating status and humidity of the air before starting work A-002 - Determine the cause of microbial contamination during the drying process and retrain the line operators if necessary Product: - The product is destroyed or used for other purposes - Who: The workers in the factory CCP-2 B: Growth of - Regularly clean and check microorganism the heat-sealing machine (B) s (especially - Workers must follow the Sealing by mold) right operation; check and heat sealer remove the incomplete sealed products The product must be completel y and properly sealed - Control the humidity of the air - What: Monitor the operating capacity of the heat-sealing machine and the humidity of the air during sealing - How: Check the moisture in the sealing area Visually check that the product is completely sealed - Frequency: Everyday -Train operators for proper operation -Stop the sealing process if the product is not completely sealed -Isolate the product if it is not completely sealed and left out for too long -Finished product inspection in each batch - Who: Operator or supervisor CCP-3 (P) Metal detector P: Metal fragments Products are put through metal detectors to remove product packages containing metal Periodically, check the metal detector by QC No metal fragments detected - What: The product for the presence of metal fragments - Identify the source of the metal found in the product and fix the damaged equipment - How: Visual examination for the presence of an operating electronic - Correct operating metal detector, magnet, procedures to ensure that the intact screen, or flotation tank product is not processed - Frequency: Continuous without metal detection monitoring by the metal detection - Rework to remove metal or separation device itself fragments from any product - Who: Visual checks to ensure rejected by the metal that the device is in place detector and operating may be performed by any person who has an understanding of the nature of the controls 18 - Check the metal detector using validated sensitivity standards daily, at the start of production, every hours during operation - Conduct a validation study to determine appropriate settings for the metal detector - Develop metal detector sensitivity standards A-003 OPRPs PLAN OPRP Significant Control measures No hazards OPRP-1 C: Chemical Raw material quality check (C) contamination can happen because of environmental pollution, inappropriate use of agrochemicals, sabotage, adulteration, residues of pesticides and pesticides OPRP-2 C: Pesticides, - Controlled by GMP and (C) toxic substances SSOP Monitoring Procedure: (What/How/Frequency/Who) Residues of What: Check the content of pesticides pesticides in the tea leaves must meet the How: Sampling to measure the standards of indicators in tea leaves Circular 50/2016/TT- Frequency: months/time BYT (Vietnam) Who: QC Criteria Take a water sample before use for testing What: Disinfect water with UV rays or OZONE, equipment sanitation How: Equipment, tools, and containers that used to contain the receiving water must be cleaned and disinfected to make sure they are free of harmful substances Corrective Action -Test the raw material Material quality months/time check sheet -QC manager checks the result sheets - Determine the cause of contaminated water source -Treat or dispose of water source - Change new water source - Make a diagram of the Water water supply system receiving - Control the operation of report the system to maintain good operation of the treatment system, protect and prevent the water source from the risk of contamination - Checking water quality: planning and taking test samples, handling problems when having results Who: QC, workers - Good implementation of GMP, SSOP - Clean and maintain the machine regularly The operating capacity of the machine during the process must meet the cleaning of leaves OPRP-4 B: L - Perform regular cleaning - Time, (B) monocytogenes, and maintenance of temperature Salmonella machines to avoid crossof precontamination chilling - Follow proper cleaning and must be sanitizing procedures properly Records - If the criteria exceed the allowable limit, stop production, isolate the batch of raw materials, contact the supplier to return the goods Recall products manufactured from that batch of material - Re-evaluate, increase the frequency of quality inspection of raw materials to months/time Frequency: Every day OPRP-3 P: Sand, dust, (P) insect fragments Verification - What: Manage the operating Finished product Process: capacity of the machine during the - Training the operator for inspection in each batch proper control process - How: Monitor the capacity of the - Use the alternative process tea leaf washing machine regularly - Re-wash Product: After the product is - Frequency: Once a day (at the found to have a problem, it beginning of the shift) should be fixed immediately - Who: The person who operates to avoid affecting the next this process process B-001 What: Monitoring freezing time, temperature, humidity, and sanitation of equipment How: Visual inspection for operating machine Control proper time and temperature B-002 19 Process: - Stop the pre-chilling process and adjust the temperature, time exactly - Determine the cause of microbial contamination -Test the chiller using standard daily temperature, at the start production, hours/time during operation per day - Humidity control is extremely important - Specific sanitizing procedure Frequency: Periodical check and clean chiller months/time Who: Process operator or supervisor OPRP-5 B: - Wash hands properly so as (B) - C botulinum, not to contaminate the E coli, product with Salmonella from microorganisms workers - Mold OPRP-6 B: - Bacillus (B) spp., Clostridium spp., Staphylococcus spp - Bacteria or mold - Personal What: Personal hygiene hygiene thoroughly and control packaging before conditions participating - How: Evaluate worker hygiene in the and ensure appropriate production environmental conditions for - Store the package in a dry - Control products at the packaging stage place and check the package the - Frequency: Every day regularly temperature - Who: Factory workers who are and assigned in this process humidity - Controlled by GMP/GHP - Clean and maintain the machine regularly - Place the product in a dry place -The automatic boxing machine must be cleaned and up to standard -The space must be dry during the pre-chilling - Check and clean the process and thoroughly chiller months/time inspect the machinery periodically by a mechanical engineer Product: - The product is destroyed immediately and used for other purposes Process - Hygiene check of - Isolate the entire product of workers before working the frozen tea concentrate - Check temperature and batch humidity for the product - Sampling product for storage environment testing to find out the cause of spoilage Product: - Disposition of product contaminated with organisms or mold by destroying or reusing it for another purpose - What: Equipment sanitation Process: Finished product procedures to prevent cross- Stop the boxing process, inspection in each batch contamination determine the cause of mold - How: The machine is cleaned and bacterial contamination properly and make sure it is placed - Contact the cleaning in a dry place department The cleaning - Frequency: Twice a day (at the maintenance plan will be beginning and the end of the shift) reviewed and changed if -Who: Supervisor necessary Product: - Isolate products that show signs of mold 20 B-003 Boxing inspection report DISCUSSION AND CONCLUSION Discussion: The process to make instant green tea powder is divided into four stages: (1) material receiving (paper box, tea leaves, water, and aluminum foil sachet), (2) handling tea leaves (washing tea leaves, rolling/griding, drying), (3) instant green tea powder processing (extraction, filtration, aroma stripping, concentration, pre-chilling, freezedrying), (4) packing and metal checking stage (packaging, sealing by heat sealer, metal detector, and labeling) For each step in the production of instant green tea powder, four hazards (biological, physical, chemical, and allergen) need to be identified To determine whether the hazards are CCP or not, it is necessary to answer four questions of the decision tree Overall, there are three steps that are considered as CCP By answering five questions of decision tree, each hazard is determined to be an OPRP or not Generally, there are six steps that are considered as OPRP in processing Non-CCP hazards: Several processing steps are not CCP because: - Some of the steps can be controlled by checking the quality of the raw materials before they are used (receiving water, tea leaves, ) - Some steps are controlled by the good implementation of GMP, GHP, SSOP, so they are CP - In some steps, they have been had measures related to the environment and a combination of control measures to eliminate or reduce hazards to an acceptable limit in the end product Several steps like pre-chilling, packaging, boxing/labeling, etc can control temperature, periodically check equipment, and put it in the proper places in the production line In addition, some steps like water receiving, washing, tea leaves receiving can also control the number of pesticides, toxic substances, so they are OPRP - Few steps in production are eliminated or handled in subsequent steps (pathogenic microorganisms can be controlled in step 13 (freeze-drying), sand, gravel can be controlled in step (washing), impurities of metal samples can be controlled in step 17 (metal detector) - Several steps are controlled by AVL/COA 21 CCP hazards: • CCP-1 (B): It is a microbial hazard that may occur during the freeze-drying step The main microorganisms are L monocytogene and Salmonella may still survive in the frozen tea concentrate The freeze-drying process is specially designed with a temperature at -35oC in hours which is far away from the ideal conditions for the growth and development of these dangerous bacteria The cross-contamination from environmental factors such as the unclean machine, the untreated processing space surrounding can lead to the welcome of some pathogenic bacteria that can be harmful to the final product Besides that, the freeze-drying step is also the subsequence step to control other bacterial hazards such as E coli microorganisms, yeasts, and molds from the filtration step, and L monocytogene and Salmonella form pre-chilling step if they may be not treated carefully For this CCP, the corrective actions are isolating the batch of frozen tea concentrate contaminated with microorganisms; destroying or using the failed product for other purposes; additionally, are determining the cause of this contamination during the freezedrying process, and retraining the line operators if necessary To complete the verification, microbiological testing must be done after each batch of the products • CCP-2 (B): It is a microbial hazard during the sealing process When the product is not completely and properly sealed, green tea powder will easily absorb moisture from the air because it has been freeze-dried, so it has high hygroscopicity Air humidity in Vietnam is relatively high, so if not controlled properly, it will affect the nutritional content and quality of green tea powder When moisture is absorbed into the green tea powder, it creates conditions for the growth of microorganisms in the green tea powder (especially mold) This hazard can not be reduced or eliminated in subsequent steps, so it is considered as CCP The corrective actions are training the operator, stopping the sealing process if the product is not completely sealed, isolating the product that is not completely sealed and left out for too long To verify it, the operation of the machine and the humidity in the air must be checked before starting work, the finished product of each batch must be inspected • CCP-3 (P): The last CCP is a physical hazard that may occur during the metal detector step The main physical hazard is metal fragments that still appear in the product Metal fragments may be detected in the instant green tea powder by an electronic metal detector However, if the electronic metal detector is not properly calibrated, processing factors such as ambient humidity may create an interference signal that may mask metal fragments Metal fragments should 22 also be considered a significant hazard at the metal detector step The hazard of metal fragments may also be controlled by passing the product through the metal detector to remove product packages containing metal Metal fragments can be removed from a green tea powder after they have been introduced by passing it through a screen, magnet, or flotation tank In addition, the metal detector step is also the subsequence step to detect another physical such as impurities of metal sample in instant green tea powder In this step, it should need to set critical limits that no metal fragments are detected in the product that passes through the metal detector Take the following corrective action if the product is involved in a critical limit deviation that reworks to remove metal fragments from any product rejected by the metal detector To verify it, the metal detector needs to be checked by using validated sensitivity standards daily, every four hours during operation Non-OPRP hazards: Part of the processing is not OPRP because: - A few steps are PRP (paper box receiving, Aluminum foil sachet receiving, ) - Some other steps are CCP (freeze-drying, sealing by heat sealer, metal detector) - Several steps have control measures that can be easily eliminated or handled hazards during production such as cleaning, inspection, concentration control, monitoring, maintenance, etc., so they are not OPRP OPRP hazards: • OPRP-1 (C): It is a potential chemical hazard that can occur during the tea leaves receiving step Details that, after harvesting, trucks with specialized boxes or trucks holding teabags transfer the tea leaves rapidly to the processing plant As a result, tea leaves can be polluted by the environment during the transit process Tea can also be influenced by chemical factors such as inappropriate use of agrochemicals, sabotage, adulteration, residues of pesticides and pesticides This hazard control measure is raw material quality check by the criteria of residues of pesticides which must meet the standards of Circular 50/2016/TT-BYT (Vietnam) The corrective actions of this OPRP are mentioned as follows if the criteria exceed the allowable limit, then stop production, isolate the batch of materials, contact the supplier to return the goods Recall production from that batch of materials, then reassesses, increasing the frequency of material quality checks to months/time Besides, verification is also very necessary because, through this work, it is possible to control the quality of raw materials received They are checked every months and QC will be the manager and check the result sheet 23 • OPRP-2 (C): It is a potential chemical hazard that can occur during the water receiving step In particular, pesticides, toxic substances can be mixed in the water that is received Thus, this hazard will be controlled by GMP and SSOP by the way that takes a water sample before used for testing The corrective actions of this OPRP are listed as follows determining the cause of the contaminated water; treating or disposing of the water source and changing to a new water source if necessary As for verification, firstly, making a diagram of the water supply system Secondly, controlling the operation of the system to maintain good operation of the treatment system, protecting and preventing the water source from the risk of contamination Finally, checking water quality: planning and taking test samples, handling problems when having results • OPRP-3 (P): It is a potential physical hazard that can occur during the washing step Sand, dust, insect fragments are things that can be left in the water used to wash the tea leaves Hence, it is necessary to perform well GMP and SSOP, clean and maintain the machine regularly Besides, the operating capacity of the machine during processing must meet the cleaning of leaves The corrective actions of this OPRP according to process that training operators for proper control After that, the alternative procedure is used Next, tea leaves are washed again About products, after the product is detected a problem, it needs to be fixed immediately to avoid affecting the next process Finally, inspecting finished products for each batch for verification • OPRP-4 (B): It is a microbial hazard that may occur during the pre-chilling (freezing) step The main microorganisms are L monocytogenes, Salmonella may still survive during pre-chilling In this step, it is specially set up with a temperature at -18oC in two hours which proper condition for inhibiting microorganisms However, if the temperature, the time is not adjusted correctly and the equipment is not checked carefully, the microbiological hazard can occur in this step Thus, the pre-chilling process must be controlled the time and temperature, there is a specific sanitizing process, especially the humidity control is extremely important because this is a condition for the growth of microorganisms For this OPRP, the corrective actions are stopping the prechilling process and adjusting the temperature, time exactly, determining the cause of microbial contamination during the pre-chilling process, and thoroughly inspecting the machinery periodically by a mechanical engineer; additionally, the product must be destroyed immediately or used for other purposes To verify it, we need to test the chiller at standard temperature daily, checking and cleaning the chiller every month periodically 24 • OPRP-5 (B): It is a microbial hazard during packaging The main pathogenic is the survival of C botulinum, E coli, Salmonella from workers, and mold during packaging control of temperature, humidity, and personal hygiene before entry into production to reduce the adverse effects of microbiological hazards The corrective actions include isolating the entire product of the frozen tea concentrate batch, sampling product for testing; and disposition of product contaminated with organisms or mold by destroying or reusing it for another purpose To verify this, we need to check worker hygiene, product storage environment temperature, and humidity • OPRP-6 (B): The last OPRP is a microbial hazard during the boxing/labeling process The main pathogenic is the survival of spore-forming bacteria (Bacillus spp., Clostridium spp., Staphylococcus spp.), and mold during boxing/labeling The boxing/labeling process is specially designed with dry space; the automatic boxing machine is cleaned and up to standard For this OPRP, the corrective actions are stopping the boxing process, determining the cause of mold and bacterial contamination; contacting the cleaning department if necessary; additionally, discard products showing signs of mold To complete the verification, a finished product inspection in each batch must be done after the boxing/labeling process Conclusion: To have good and quality instant green tea powder products, besides a properly designed manufacturing plant layout, a suitable product manufacturing process The products must meet the standards of HACCP, ISO 22000, as well as be assessed for risk and identified hazards by the HACCP plan and OPRPs plan which focuses on hazard identification, assessment, and control so that the hazards can be identified, assessed, and then the appropriate corrective actions and control measures for these hazards will be applied REFERENCES Bourdoux, S., Rajkovic, A., De Sutter, S., Vermeulen, A., Spilimbergo, S., Zambon, A., Technologies, E (2018) Inactivation of Salmonella, Listeria monocytogenes and Escherichia coli O157: H7 inoculated on coriander by freeze-drying and supercritical CO2 drying 47, 180-186 Sinija, V., Mishra, H., & Bal, S J J o F E (2007) Process technology for production of soluble tea powder 82(3), 276-283 Huang, M., & Zhang, M (2013) Tea and coffee powders In Handbook of Food Powders (pp 513-531): Elsevier Park, J., Back, C., & Kim, J (2005) Recommendation of packing method to delay the quality decline of green tea powder stored at room temperature Korean Journal of Horticultural Science & Technology, 23(4), 499-506 25 Chen, H., Liou, B.-K., Dai, F.-J., Chuang, P.-T., & Chen, C.-S (2020) Study on the risks of metal detection in food solid seasoning powder and liquid sauce to meet the core concepts of ISO 22000: 2018 based on the Taiwanese experience Food Control, 111, 107071 Avila-Sierra, A., Zhang, Z J., & Fryer, P J (2019) Effect of surface characteristics on cleaning performance for CIP system in food processing Energy Procedia, 161, 115-122 26 27 ... and a vacuum pump Instant green tea After going through the above steps, the tea leaves have been made powder into instant green tea powder Packaging is the stage soluble tea powder that will... nutritional content and quality of green tea powder When moisture is absorbed into the green tea powder, it creates conditions for the growth of microorganisms in the green tea powder (especially mold)... suitable 9 10 11 12 Steaming: The method comprises the following steps of pre-dissolving the tea raw materials such as tea leaves, tea stems, and tea residue, performing steam explosion under