(Đồ án hcmute) analyze reality quality control of roasted and ground coffee at quang tung coffee manufacture factory

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FINAL THESIS INDUSTRIAL MANAGEMENT MAJOR ANALYZE REALITY QUALITY CONTROL OF ROASTED AND GROUND COFFEE AT QUANG TUNG COFFEE MANUFACTURE FACTORY INSTRUCTOR: NGUYEN THI ANH VAN STUDENTS: NGUYEN THI THU HIEU ID STUDENTS: 16124023 STUDENTS: NGUYEN THI BICH HAU ID STUDENTS: 16124019 SKL 0 7 Ho Chi Minh city, May 2020 Luan van MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING FINAL THESIS TOPIC: ANALYZE REALITY QUALITY CONTROL OF ROASTED AND GROUND COFFEE AT QUANG TUNG COFFEE MANUFACTURE FACTORY Students : Nguyen Thi Thu Hieu – 16124023 Nguyen Thi Bich Hau - 16124019 Year : 2016 Major : Industrial Management Instructor : MBA Nguyen Thi Anh Van Ho Chi Minh city, May 2020 Luan van THANKS TO With deep gratitude and grateful, the author would like to thank Ms Nguyen Thi Anh Van for wholeheartedly supporting and guiding the author in the entire internship process Her helpful tips helped the author to better complete the assigned tasks during the internship/ internship report and the final thesis also In addition, the author would also like to thank the leaders of Quang Tung Coffee for creating the best conditions for the authors to have the opportunity to study and experience practical work Sincerely thanks to the brothers and sisters in the company for creating favorable conditions during the author's internship at the company And especially, the author would like to thank Mr Le Thanh Tung for wholeheartedly supporting and guiding the author in the entire internship process His helpful advice has helped the author to better complete the assigned task and his suggestions and guidance have helped the author to complete this report Sincerely thanks! Ho Chi Minh city, 5th May,2020 Students Nguyen Thi Thu Hieu Nguyen Thi Bich Hau i Luan van LIST OF ACRONYMS ACRONYMS EXPLAIN QM Quality management QC Quality control QA Quality Assurance CCP Critical Control Points HACCP Hazard Analysis and Critical Control Points PE Polyethylene GMP Good Manufacturing Practices SSOP Standard Sanitation Operation Program CP Control Point CL Critical Limit TQM Total quality management ii Luan van LIST OF TABLES Table 1.1: The business results Table 3.1: Check the quality of coffee beans after roasting 36 Table 4.1: Product description 47 Table 4.2: Benchmark for sensory evaluation 54 Table 4.3: List each hazard in the process of controlling roasted coffee (Refer to appendix 1) 56 Table 4.4: Identify critical control points (Refer to appendix 2) 56 Table 4.5: Setup CCPs (Refer to appendix 3) 56 iii Luan van LIST OF FIGURES Figure 1.1: Company’s logo Figure 1.2: Company’s Organization Figure 1.3: Company’s products Figure 3.1: Green coffee is shipped from the warehouse 32 Figure 3.2: Technological process at Quang Tung coffee 33 Figure 3.3: Roasting machine 35 Figure 3.4: The change of colors 36 Figure 3.5: Cooling machine 37 Figure 3.6: Packing machine 39 Figure 3.7: Product after being packed 40 Figure 4.1: More modern machines at small companies 41 Figure 4.2: Coffee brewing tank in according to new technological process 42 Figure 4.3: Technological process 48 iv Luan van TABLE OF CONTENTS THANKS TO i LIST OF TABLES iii LIST OF FIGURES iv TABLE OF CONTENTS v INTRODUCTION CHAPTER 1: INTRODUCTION ABOUT COMPANY 1.1 General introduction 1.1.1 Information about An Khanh Trading Service Company Limited and Quang Tung coffee manufacture factory 1.1.2 The process of formation and development 1.1.3 Vision, mission and core values 1.2 Business fields and operations of the company 1.2.1 Business products 1.2.2 Operation and business results 1.3 Advantages and disadvantages of the enterprise CHAPTER 2: LITERATURE REVIEW 2.1 Quality and quality management 2.1.1 The concept of quality 2.1.2 Quality management 10 2.2 The quality management methods 15 2.2.1 Quality verification strategy 16 2.2.2 Quality control 17 2.2.3 Total quality control (TQC) 18 2.2.4 Total quality management (TQM) 19 2.3 The basic content of quality management 20 2.3.1 Quality planning 20 2.3.2 Quality control 21 2.3.3 Quality assurance 22 2.3.4 Quality improvement 23 2.4 The factors impact directly to product’s quality 23 v Luan van 2.5 Hazard Analysis and Critical Control Points (HACCP) 26 CHAPTER 3: ANALYZE QUALITY CONTROL IN QUANG TUNG CAFE MANUFACTURE FACTORY 31 3.1 Quality control of input materials – green bean 31 3.2 Quality control during production 33 3.2.1 Cleaning 33 3.2.2 Roasting and cooling 34 3.2.3 Mixing 37 3.2.4 Grinding 38 3.3 Control the process of packaging and finishing products 39 3.4 Comment on the advantages and limited in the quality management process of Quang Tung coffee manufacture factory 40 CHAPTER 4: PROPOSE SOLUTIONS FOR IMPROVING QUALITY CONTROL AT QUANG TUNG COFFEE AND AN KHANH TRADING CO., LTD 41 4.1 Changing modern machinery and technology process 41 4.2 Recruitment of quality control staff for manufacture factory 42 4.3 HACCP construction for coffee roasters production line 46 4.3.1 STEP 1: ESTABLISHING A WORKING GROUP ON HACCP 46 4.3.2 STEP 2: PRODUCT DESCRIPTION 47 4.3.3 STEP 3: TECHNOLOGICAL PROCESS 48 4.3.4 STEP 4: DIAGNOSTICS AND SURFACE PLAN BY GMP RULES 49 4.3.5 STEP 5: IMPLEMENTATION SSOP 50 4.3.6 STEP 6: HAZARD ANALYSIS 51 4.3.7 STEP 7: DEFINE CCP 56 4.3.8 STEP 8,9,10,11: SET UP CCP 56 4.3.9 STEP 12: ESTABLISHING DOCUMENT SYSTEMS AND RECORDS 56 CONCLUDING 57 REFERENCES 58 APPENDIX 57 vi Luan van INTRODUCTION Introduction Vietnam is an agricultural country with a large number of agricultural products with an important position in supplying agricultural products to the world such as tea, coffee, rice, pepper, etc Cultivated in Vietnam for a long time, there are still problems that inhibit the development and affirm the brand name in the international market We have achieved the second largest export volume of coffee in the world, only after Brazil, but the competitiveness is always lost in terms of quality, price, mostly unofficial raw coffee Therefore, Vietnamese coffee has not fully developed its ability to create a certain brand in the world According to the author's research, in addition to a few big companies that are always mentioned such as Trung Nguyen brand or Vinacafe, small coffee production companies in Vietnam are quite many, operating by region and region In Can Tho City, where the author has time to learn about economic activities here, there are many companies and establishments producing coffee in the form of small, mainly with equipment, machinery as well as rules old production process During the internship at the company, the author had the opportunity to approach the real working environment and gain a deeper understanding of the quality management knowledge learned in the classroom With the help of instructors Ms Nguyen Thi Anh Van and Mr Le Quang Tung - direct instructors at the company, the author hopes to have successfully completed the enterprise environment experience, built up the ability to create plan and improve knowledge and skills, especially in the quality management system Along with the desire to be able to contribute to the development of production facilities in terms of quality, build a brand of Vietnamese coffee with more brand value, pay more attention to the quality of products, the author has chosen topic: "Analyzing quality control of roasted coffee at Quang Tung coffee." Research objectives Applying a combination of reasoning with an analysis of the company's actual conditions, based on an assessment of the company's advantages and disadvantages, outstanding issues and their causes deals in quality control activities From there, the Luan van author during an internship at the company will give some suggestions and solutions for the company's quality control activities Research scopes − Research location: at Quang Tung coffee manufacture factory belonging to An Khanh Trading and Service Co., Ltd − Research activities: focus on studying the quality control activities of the company, at the same time combined with the general economic development of the Southern market to compare and suggest solutions The most optimal for the company's quality management activities − Duration of research: months Research methodology ❖ Methods of data collection − Secondary information source: Reference documents are company reports, information on newspapers, internet, and essays in the library of University of Technology and Education of Ho Chi Minh City This is a desk method, this study is purely based on judgment and reasoning to come up with solutions to the problem − Primary information source: Observing the actual situation, directly working at the company's production facilities to understand the operating model, the way of doing business and assess the actual situation at the company ❖ Methods of statistics and data aggregation From the information collected during the internship and data through observation, direct participation that conducts synthesis and planning development Final thesis structure The structure of the report consists of chapters: Chapter 1: General introduction about An Khanh Trading and Service Co., Ltd., Quang Tung Coffee Production Facility Chapter 2: Analyzing the status of quality control work in the company Chapter 3: Solutions to perfect the quality control system Luan van gas, by vacuum or a combination of vacuum and gas However, according to the researcher when roasted ground coffee is packaged in a vacuum condition, it can be kept all volatile compounds such as ether, oil, CO2, and coffee moisture content of about 1,5-2%; at the same time, under vacuum condition, it still retains the typical taste of coffee and gives the diffusion of these compounds more perfectly than conventional methods Francesco Illy also argued that the oxidation of fat compounds and coffee oil is still unavoidable (albeit very small) because the extremely small fractions are immediately oxidized by the air, followed by Chemical combination between oxygen and fats and coffee oil to start the oxidation process The amount of oxygen absorbed during oxidation is difficult to be removed during vacuum extraction According to the researchers, if the vacuum packaging is not damaged, the quality of coffee can be maintained for a period of 18 months without the need to apply any special preservation measures But when opened, keep the coffee bag in the fridge and use it for a short time If you want to use long can handle frozen coffee pack - Grinding: In the process of grinding roasted coffee, people usually proceed through stages: • Break the roasted coffee beans into relatively large pieces to release the remaining silk • Crush the above coffee pieces to a smaller size (according to consumer demand) • Homogenize (or normalize: normalized) to mix evenly between silks and roasted coffee beans; at the same time creating roasted and ground coffee products with uniform coloration as well as making the coffee juice thick The homogenizer is a stirring chamber made of paddle stirrers, normally mounted in the grinding equipment According to Steven J Kirkpatrick, in the process of grinding the following steps will result in higher quality roasted coffee products: - Step 1: Ideally, roasted coffee is broken to about 40-80% broken size on a 6-mesh (3.36 mm) sieve, then most of the silk on the coffee beans will be peeled off If more than 80% of the fragments on a 6-mesh sieve are too rough, it is difficult for the silk to peel off completely; If less than 40% of the debris is retained on the mesh sieve, then the fragments are too small to give the final product a large density 55 Luan van - Step 2: After being broken into pieces as above, homogenize During the homogenization process, the remaining coffee pieces and silk peels are mixed together, the coffee oil that is released from the coffee fragments blends with small pieces of silk, creating a feeling of having no silk on background of roasted coffee Here we can add more fragrances or additives Usually this step is done in a very short time, only a few minutes It is these two steps that contribute to reducing the density of roasted coffee products The last step is to grind the coffee in the two steps above to the desired size Table 4.3: List each hazard in the process of controlling roasted coffee (Refer to appendix 1) 4.3.7 STEP 7: DEFINE CCP Table 4.4: Identify critical control points (Refer to appendix 2) 4.3.8 STEP 8,9,10,11: SET UP CCP Table 4.5: Setup CCPs (Refer to appendix 3) 4.3.9 STEP 12: ESTABLISHING DOCUMENT SYSTEMS AND RECORDS − The company must establish a documented system of all operational procedures of the HACCP program appropriately − References and documentation − Production, prevention, improvement, procurement, and distribution plans − Test plan, control processes − Marketing, market research − Personnel organization − Working environment − Report and approval of management 56 Luan van CONCLUDING Although the same object is coffee, there are three different actors interested in coffee quality Here we can give three specific subjects with the same flavor of the object as coffee: For producers, the quality of coffee means that the physical and chemical parameters of the coffee meet the level Technical and quality specifications have been set for the product For the seller, quality is in the eyes of the buyer For coffee drinkers: the quality of coffee fish is the set of characteristics, characteristics or attributes contained in the coffee water, meeting their drinking needs, depending on each market The characteristics of coffee include: basic flavors such as natural aroma, bitterness, acrid taste, sweet and sour taste, greasy feeling and aftertaste; strange flavors due to the mix and the overall appreciation of the tasting house as the concentration of each type of flavor, the harmony between these flavors and the deliciousness of refreshing spirit The development and quality control of roasted ground coffee contributed significantly to creating brand value for each company in particular, and also contributed to increasing the export volume of roasted coffee, positioning the quality of coffee and Vietnamese coffee in the world market 57 Luan van REFERENCES Crosby, P B (1979) Quality is free New York: McGraw-Hill Deming, W E (1982) Out of crisis Cambridge, Mass: MIT Press Feigenbaum, A V (1961) Total quality management New York: McGraw-Hill Ishikawa, K (1985) What is Total Quality Control? New Jersey: Prentice Hall Juran, J M (1974) Quality Control Handbook New York: McGraw-Hill Le Thuy An, Le Thi Dieu, Nguyen Thi Hong Ban, Do Thi Thu Hang (2011) Learn technological process of producing powdered coffee Nguyen DInh Phan, Dang Ngoc Su (2012) Quality Management Ha Noi: University of Economic Nguyen Thi Luu, Nguyen Thi May, Pham Ha Ni (2015) Building HACCP system for beer factory Nguyen, N T (2010) Quality management of bean green coffee at Ha Lan Co,Ltd Master dissertation, Da Nang University 10 Pham Tran Ngoc Hanh, Nguyen Thi Tra My, Le Thi Mui, Nguyen Thi Ngoc Mai, Tran Ha Ngoc Ngan (2012) Three GMP process for roasted and ground coffee manufacturing 11 Ta Thi Kieu An, Ngo Thi Anh, Nguyen Thi Ngoc Diep, Nguyen Van Hoa, Nguyen Van Kiet, Dinh Phuong Vuong (201o) Quality Management Ho Chi Minh: Thong Ke Publisher 12 Vietnambiz (2019) Report of the coffee market in November,2019 58 Luan van APPENDIX Appendix Table 4.3: List each hazard in the process of controlling roasted coffee Sep Steps Material Hazards - Control Measures Bacteria: Checking ✓ Fresh coffee growing and Particles with uneven colors; there are processing facilities check many punctured seeds, tiny seeds, black Men Yeast: seeds, moldy seeds, Mold Insect pests Sand, gravel, metal, black grain, musty seed, young seed ✓ Fresh coffee growing and processing facilities check Check by senses The degree of change of chemical - Test by the senses (roasting - If roasted yet, the seeds will be pale, compounds, the degree of roasting temperature roughly 200-240oC), medium brown If roasted excessively, the is not reached or excessive, all even browning on the grain surface grain color will tend to turn black affect the quality of products Roasting In the case of polished seeds, the -If roasted at low temperatures, the aroma entire surface of the beads is smooth has not been formed If the temperature is and smooth, if there is any residue too high, the aroma is lost many times of silk, there is a little silver color, roasted, the taste increased no pests, no black dots, no mixed roasted seeds 57 Luan van Check by senses (cooling - The aroma decreases and if it does not cool temparature roughly 28-30oC) Cooling in time, the color of the grain will darken at the end of the roasting process, the taste will decrease Remaining rice ✓ husk and silk - Sampling of coffee preparation, -If grinding is too large, the coffee extract coffee residue (not yet peeled off of tasting roasted coffee) preparation equipment that particle substance If grinding is too fine, the water Grinding ✓ (depending on the will go down quickly, poorly soluble size varies) mixed through the flour layer is slow, the - Check by sense htu water is cooled, making the aroma of coffee does not diffuse completely -The status of the grain is uneven if leftover silk grass in large quantities Moisture absorption from outside, - Sensory examination, sampling -Products have mold, loss of aroma, sour penetration of air oxygen, sunlight for tasting preparation Preservation reduces product quality 58 Luan van taste Appendix Table 4.4: List each hazard in the process of controlling roasted coffee Sep Steps Hazards Question 1: Does Question 2: Is this Question 3: Question 4: Whether the this control exist stage specifically Does the hazard next stage removes or at this stage? designed to limit or exceed the reduces the hazard to an reduce the probability acceptance limit acceptable level of a hazard to an or go to an acceptable level? unacceptable CCP limit? Material -B microorganisms -No No occur No occur No occur Not CCP that damage the Establishments material planting and -B pathogenic processing fresh As above As above As above Not CCP microorganisms coffee cherries -C Pesticide -No (As above) As above As above As above Not CCP -No (As above As above As above As above Not CCP -No As above As above As above Not CCP residues -P impurities 59 Luan van - CP Extraction rate of chromium Yes (Sieve test) Yes No occur No occur CCP1(CP) - C level of Yes Check by Yes No occur No occur CCP2 (C) chemical compound sense Yes No occur CCP3(P) No occur No occur CCP4(C) compounds and their Roasting loss change Grinding Packing -P impurities Yes Check by No sense -C the penetration Yes By sensory, Yes of oxygen, light, and concocting, moisture leads to tasting oxidation Appendix Table 4.5: Setup CCP Steps Hazards CCP Following Content Variable degree Roasting of chemical Roasting Roasting temporature temporature Method Frequency Thermometer 1min/ once compounds Corrective Executer Luan van action Manufacturing Adjust the Evaluation staff machine team HACCP QC Staf 60 Confirm Cooling Grinding roughly 200- of green Isolate and (1 240oC coffee handle week/once) Time from 5- Roasting 20min time Chemistry: Cooling Cooling oxidation of temporatue temporature aromatic 28-30oC compounds Time from 3- Cooling time The level of Temporature: Grinding extraction of 18-20oC temporature compounds and Time: 8- Grinding their loss 10min time Default Before Manufacturing manufacturing Staff Thermometer min/ once Isolate and handle Manufacturing Isolate and staff handle QC Staff Default Before Manufacturingg Isolate and manufacturing staff Thermometer aromatic Default 61 Luan van handle Appendix 4: Technical requirements of roasted coffee ( TCVN 5250-90) Quality level (% weight) Name indicator Level I Level II Sensory The seeds are uniform, nonForm flammable, allow to stick some silks of silvery sheen Color Odor Taste Water mixed The seeds are uneven, allowing some silk sheaths to stick Dark brown Dark brown Unique aroma of roasted Unique aroma of roasted coffee, no strange smell coffee, no strange smell Strong taste, rich physical, Strong taste, average body, no attractive strange flavors Dark brown, clear, attractive Dark brown, clear, attractive and attractive and attractive Physical & chemistry Good nuts > 92 > 86 Fragments