wy t ` gể he ky si ý a Brussels School eS
4 Economics & Management rò
Master in Business Quality and Performance Management | | FINAL REPORT Subject: y | Y ee
ENHANCING QUALITY MANAGEMENT CAPACITY IN TRA FISH- BASA FISH IN HUNG CA COMPANY LIMITED say ae # Ì 4< << — ====== Instructed by: Dr Jacques Martin —=== =
Student > Tran Quoc Truong
Trang 2STATEMENT OF AUTHORSHIP
I certify that this project entitled “Status of Quality Management and proposal for enhancing quality managem¢ capacity in Pangasius Hypophthalmus (Tra fish) — Pangasius Bocourti (Basa fish) in HungCa company limites is my responsibility to manage and development
Except where reference is made in the text of the project , this project contain material published elsewhere
extracted in whole or in part from a project by which I have qualified for or been awarded another degree No other person‘s work has been used without due acknowledgement in the main text of the project
Ho Chi Minh City, September 2014
Tran Quoc Truong
Trang 3
ACKNOWLEDGMENTS
I would like to express my deeply thankful to Dr Jacques Martin who has been providing tk fully support and direction in this final report I hereby express my thanks for his sustain efforts j providing knowledge and teaching during the course which has benefited to all members
I am thankful to all professors and lecturers who taught the syllabus for master degree i business quality and performance management to me
Warm thanks to Ms Hien and Ms Thuy — coordinators of the program - who made the gre; connection between me and the course
I am also indebted to my colleagues and classmates to support me about performance apprais; process or contributing their opinion or sending the material to me for my report, especially M Nguyen Van Thien, my classmate to MBQPM3 class
I would like to thanks to my family who have support and encourage me all the time in thị course And finally, I offer my regards and blessings to all of those who supported or encouraged m in any respect during the completion of my report
Tran Quoc Truong
aT
Trang 4TABLE OF CONTENTS
PART A: INTRODUCTION OF HUNG CA COMPANY LIMITED .- 55555555 L¡ F.ĐWOIWWDIHỗtntahuihbridttiiiktagg10GL360L2A,1604100ELLGIÁ6G1ảãu830464-3530380uã<k9Ä/3504i0xamfidierrosotorxrmnremli=EmororerrergtoHrt ion gi rơm 7
ao CƯ TY gií TGETDHRE[DHT suanuagnrgtndtinitgiantinustiDigoets109000S00010001380054695401000138/808900/00°-g00006f8401494000/g03040/00013810Ø.8 7 a Overview bài 9) n ốốố ố ẻốốố d b General information of the Company’s development process from establishment date 10 Oy PUBOHORS B10 CUES a coccsxass.cesemascasnonaanncweass casas caneans sa sanandsasnnaanitans arabenndrdadanpanaacssiiadewnondawashandies 11
a Structure of management apparatus .cecceeseceseeeeseeeeseeeeeeceeeeeeeseeeeseeceaeeceseeseeenseeetaeenes 1] b Functions and duties of each deparfI€IĂ c1 1313332251131 1122511111118 1 111 xe 12
PART B: ENHANCING QUALITY MANAGEMENT CAPACITY IN TRA FISH - BASA FISH IN HUNG CA COMPANY LIMITED ssscsssssnsscssssssssaccsssassasssosscenseansacenvetnvenensseverresensennovanannenntsns 13 CHAPTER I1: FISH PROCESSING TECHNOLOGY AND EQUIPMENT 13
1,1 Processing TechnoÌOgØV s- << << 9.9.9.9 9 59 nọ cv ge øg 13
BAN na ốốố 䚣Ãäẽ 13
a Biological characteristics of Pangasius Hypophthalmus and Pangasius Bocourti 13
b Purchase of raw materials .cccccssssssessesesscscsssscsecscssssssecsscscsessseecsesacsecetsceecaeescacersaes 15
Mon HH 15
d Preservation OŸ maf€rIAÌS -¿- 2+ t3 3 22323 E21 121 1 1 11 111 111 111 1n nếu 15 e Perishing phenomena of raw ImaferiaÌS ¿+ + 2 S2 S6 1E SE 8E 8E 11111 53 53 c2 17
f Identification and evaluation of quality of raw materiaÌS - ¿- 6+ ss s2 £+E E2 £se£zzcczz
1.1.2 PfOC€SSITE Sàn S11 TT TH TH TH TH TH TT HT TH ngàn 18 1.1.3 Main production aT€8S - -ó- 2c 2c 212211211211 11211 11 111 H1 HT TH HT TH TT nàng 19 a Worshop I: FIÏleting - + c + sc + 221261211511 211 11 511 11 51 vn HH TT HT nay 19 b„ Worse 2: SHAG cnccnsncsccenesseninectssa sithinisansancencunesurenaranersvavencpnrgeeeeeeereresmmsseacernis: 21 C Worshop 3: MOIding cc eeeeseescescsseseeseeseseeseesecsecsccscsassscescsscsscnscsevaccaeseceareavaecaeeacaeeas Ze
d Worshop 3: Finished prOdUC - ¿+ 2c 222322 S322 123 51 1 11 11 1 1 1 111 11111 111 xe 26
Ld FRCEZING SY MCC sssssccsscscncsascnsesvansrsonsvseeserrersensensnvensaneerenreneverausenesnecsenssaavenunasannersunusensvexcasntiogbos 28
LZ What ig TOA G7 a sasssxsnenixssssincaarsataencenenncnesacraxeeneonenenvernexnoxssapevenveyeeteenessussswenesesanconssnae 28
1.2.2 Why to Íreeze s€afOOC c1 11211221121 21 12011211 ng ng ng ng can 28 1.2.3 Freezing mechanism in frozen ÍOO( + c5 1S E111 218 18 11 11 111 1E ng ghe 29
CHAPTER 2: STATUS OEF QUALITY MANAGEMENT << 55 5S se se 30
2.1 Quality management in the cOrpany -¿- ¿+ %2 1221 S2 3E SE SE SE c gx cxsryy 30 2.1.1 Applied quality standarS - -¿- cá 1 13221211 211211211 111011 11H TT HH nếp 30
si 1 B 30
ð§Ð se, g8 g ÔÔỎ 30
=0) 00 - 31
2.1.2 Some criteria for frozen fillet products of Pangasius Hypophthalmus and Pangasius BOGOUTEL cnnnsennansemscunsnsnanavavinniacthsasckinaaantamenneamnnx nhpterteinynvetiSi-eLEESUEDEEISSS01190000000107506008010006500/018500052816 31
A SONSOTY COCO sansosnensuansvasnssaxonnsnsnasiesesnwsnehin.d:tadtnstsnaasarnvanneunannsenenveaonmneneuventsspnesvensenpessins 31
b Chemical CFIt€TIOTN - óc 2c 2321 2131121311211 1 1 11 1 11 1 1111 HH HT TT TH TT nếu 32 C Microbiologicall CTIt€TIOI -:- c- 2c 2c 2211211211 1E 11 11 11 1 11 1111111110510 1E 11g gu 32 2.2 Food hygiene and safety in Pangasius Hypophthalmus - Pangasius Bocourti processing 32 2.2.1 Waf€T SUDDÏY 2 2c 2 1211211211211 21 H1 H1 HT TH HT TH TH TH T TT Tư cay 32
A Water requireMent 8n HH 32
Trang 5CHAPTER 3: PROPOSAL OF MEASURES TO IMPROVE QUALITY MANAGEMENT 3§
3.1 General comment and assessment of current quality management at the plant 34 me ẽẽố ẽố ẽ ẽố NT NA NỀN NY ABBE 34 3.1.2, Weaknesses ssscsvassorsissssonenesecesorsessessssusssssessenssastsassssteseesesssassssveensesoseseeseses,,,,,, MORE 39 3.1.3 Causes of weaknesses c0 c2 22tr 38 3.2 Proposal of measures to improve QUALITY MANAGEMENT cccccsssssssssssssesssssescoseess 39 l9 (0 CC ASGQUQ 69 REFERENCES ằỏồầồầ7ầ7ẰẤẶóá/1,11 69 INDEX 1: Figures Figure Ì HT HH Hee ổ Figure 2 HH Hee DO 8 na ,.75ĂẦ55g , HA 9 — ề.ẻ ề Q 9 "5>" 10 PAGUIC 6 .-cveveroonvenssvssensssnnsisessansasvuscoecesssnngsesueyssnnssosvretbthsnvsssecacnevereensranveavnagennantdeneeesccce , , oe 13
PAQULG Ts xsscocnnveruonnnesonassunaresnssinvsitskinsecoreneevrensnnyssesnensseustnsbitsnsaneeneaneneeverenayvenstenseranneceeescc,,, ATE 16
PAINE 8 sx cnsexcscscasnnnmeernesensnnenrseanrstsens¥ihinbnseonenceeveyyebuteenuvansvapnbtiunhiedshinnesscansenemyerereneesamesasesc, MEE 17 FÌgure 9 tt HH0 Hee 18 "E61 Q.1 19 Gv 775757 NHA, 19 "2 .ề HN 21 Figure 13 .ssseesssssssescessssessessssssscssssssssesssnsssesessussesessssssesssssussessnuusssssssesssssstiesssssteeeceeseeecccc 23 Figure Í4 HH 1111118111 tre 23 FIgUte 15 -evsvorresvceessssncesessivessanavas evonennessyannnnitnoqzvnsavaeedsissasenneeerenue yeneevvonsentaveenseasaeesscasecce hee 26 lo ẰA6DDỤDD aAAẽ 33 1" 36 Figure: 18 .sc-avessssrsvesosonsssstsossoesocssssueevoreqneeessnsnutessvvnisassnoneceeceeureemseuera ervasssnennnumutoensascisscicsiutte 50
FAQS 19 sssscnensnssnnnrensccevascncerventsiisdssaeeoneeeesevmecerapnensnit¥sdbondb Sti ouecaneeoreemeovyrenanweennemmedans decks aE of 2 ống 37 2n cố aaAAAa A4 4 38 ch ƠỮỪỚẰÖẰỀ7~ờ-‹`ậdd.1A 39 TabÏe Hee 28) TADIe 2 assccsrosessssnnnvreensasesesnsnsssensvssiscecnesnesersnnsnseresenrsvunatansniseatenuseesesaneeeseeavueesnsanmesnsaseescerecs ie 31 ốốốốỐ ãốôanh GÀ AI II AAR 32 .c ằừằừ.ầ.7ẮẰẮẶẮ.Ạ.ỘỐ.A.A1 32
THÍ 5 sscasscrazinis unoneearnrsoutceeststhtarspsaensbonnannneeyneeperestGaHen tants ta anens sannmenpeensayecentmceeose EE 36
TBE 6 onssavesnnesanennrvornnvensscetstcgsvesniu hanenonseurveonreseronensndsivdtdeainbksttsaneesansesnennepanateeesemweaeresiccouchie 36
l XI và 7.7 4 : A : 61
Trang 6PART A: INTRODUCTION OF HUNG CA COMPANY LIMITED 1 FOREWORDS:
Fisheries have long been one of key economic sectors of the country, in which frozen fillet
Pangasius Hypophthalmus (tra fish) and Pangasius Bocourti ((basafish) are staples
Strong development of Pangasius Hypophthalmus and Pangasius Bocourti culture in Mekong Delta has brought here tremendous fishery benefits Together with this development is the advent of a mass of Pangasius Hypophthalmus and Pangasius Bocourti processing companies The problem to be posed is how to raise the value of Pangasius Hypophthalmus and Pangasius
Bocourti to increase incomes for people to order to encourage them to expand culture area to
obtain abundant output for processing To achieve this goal, it is necessary to boost export through close quality management from culture to processing to meet strict quality demands of the world market and create new products for the common goal of diversifying aquaculture products, meeting increasing demands of consumers and ensuring food quality and safety for everyone
With strengths in raw materials, modern equipment and technology, skilled workers and quality management under HACCP standard, Hung Ca company's quality of products is always guaranteed to meet increasing demands of customers
With a desire to apply the learned knowledge as well as contribute a small part to improving quality of frozen fillet Pangasius Bocourti products, I have made the topic with the contents above to improve the management and control of the plant’s fish processing
2 History of formation
a General information about the Company :
Hung Ca Co., Ltd was official established in February 2006 in Thanh Binh Industrial Zone, Dong
Thap Province with 250 ha of farming area and the investment capital USD 45,000,000, at the present, spending seven years establishing and development, Hungca becomes one of Vietnam’s most prestigious and biggest companies in cultivating, processing, exporting Pangasius Nowaday, Hungca owns the farming area increases up 700 hectares across 5 areas in DongThap province such as Hong Ngu, Tam Nong, Thanh Binh, Cao Lanh, Tan Hong, includes 80 hectares and certified by “Global G.A.P” Hungca is proud of one of these enterprises which have the largest
Pangasius farming area in Cuu Long delta
NSCOR MME ARP ACURA DE ETL METIS EU AESLCER EAN TTL TSS D I ISOLA OAS UH RNS ES CS ES ES OU A DENSE BIS BC US NE USER RN
Trang 7
Figure 1: Hungca factory and Van Y factory, reaching the total capacity of 370 MT of raw material/day
Figure 2: With 700 hectares farming area in Hong Ngu, Tam Nong, Thanh Binh, etc HUNGCA becomes one of the companies that have the biggest Pangasius farming area in Mekong Delta
Trang 8
Figure 3: Global Gap farm area
Aim to supply the best Tra & Basa products, HungCa applied the international certificates as: ISO
2000:2005, BRC certificate, HACCP, IFS, HALAL, GLOBAL GAP and ASC - (Aquaculture
Stewardship Council which is published by WWF and IDH) for HungCa factory and farming areas
GLOBALG.A.P The Global Partnership for Good Agricultural Practice
Figure 4: International farming and processing standards HACCP, BRC, HALAL, ISO 22000, IFS, GLOBAL GAP
Specializing in Tra & Basa Products such as Pangasius fillet, portion, skewer, steak, roll, value added products and industrial block, Hung Ca is the top supplier of many importers all over the world With more than 4,000 young and skillful workers and excellent specialists, by each product, Hung Ca gives the best message of quality, prestige and professional
Trang 9
Figure 5: With main functions in cultivating, processing, and exporting Pangasius fillet From then, Hungca brand has been presented in many countries over the world and got significant successful in seafood field
b General information of the Company’s development process from establishment date :
» 1979 Beginning |
With more than 30 years experienced in farming Basa & Tra Pangasius fish in Mekong delta, Mr Tran Van Hung — Hung Ca founder carried out to exploit a large number of canal areas in Hong Ngu
— Dong Thap, starting in to farm and exploit in large scale
» 1989 Expanding farm scale
Expanding farm scale, focus on Thuong Lai Commune, Hong Ngu District, Dong Thap Province
The harvest capacity is about 70 MT per day, providing mainly for domestic market
» 1992 Investment
Trang 10
Investing in farming in floating raft, including 9 big rafts, providing 100 — 300 MT Pangasius raw
material for the processing factories
1996 Development
Widening the lake and raft’s area, standardizing farming and production 2003 Turning-point
Dong Thap Province appealed for developing the farming seafood career in alluvial flat HungCa
invested in dredging 34 ha hillock in Tan Thanh and Tan Binh Commune, Thanh Binh District in order to continue to expanding the farm
Besides expanding the farm, HungCa focuses on improving the fountain-head, raise fish by industrial feed meal made from broken rice, bran, marine fish that improved the fish’s quality, reduced farming
cost, enhanced the cost price, tended to the exportation
Getting successful in farming and providing high quality Pangasius raw material, HungCa built the prestige gradually in the seafood field and tended to expand the distribution channel, especially in exportation
2006 Hung Ca Establishment
April 2006: Hung Ca built the processing seafood factory in Dong Thap Province with capacity 45,000 raw material per year that completes Hung Ca’s close process: Farming — Processing —
Exporting From then, Hung Ca became the unique exporter which had close process that helped
control the raw material and be flexible in exportation
6 Feb 2006: Hung Ca Co., Ltd was official established with 80 ponds along Hong Ngu, Tam Nong and Thanh Binh, and | processing factory with capacity 50,000 MT per year
26 Dec 2006: Hung Ca Branch was founded in Ho Chi Minh City Hung Ca Products, Pangasius fillet
has been launched in the international market, especially in Europe, Middle East, Russia, Asia, South America
2008 Achievements
Hung Ca got the EU code — DL 126
Hung Ca got many certificates continuously including: ISO 22000:2005, BRC, HACCP, IFS 2010 Improvement
June 2010: Hung Ca is one of six companies who get Global Gap certificate that helps Hung Ca penetrate easily to the strict markets and consolidate Hung Ca trade mark in the international market
August 2010: Putting the second Seafood processing — Van Y in operation with the capacity 80.000 MT per year, getting the total capacity 120.000 MT per year
Trang 11b Functions and duties of each department
- Board of Directors is the highest unit which has power to manage all activities of the company
in accordance with plans, policies and laws of the State
- Sales Department: acts as a counselor for the Board of Directors on production, raw material
plan; coordinates with the Export Department to seek customers at home and abroad; associates with the Quality Control Department to check sanitary condition and maintenance of equipment
for production
- Farming Department is responsible for managing and providing raw fish for Supply
Department
- Supply Department: is responsible for providing input materials as required by the plant
- Production Executive Board: coordinates with departments to regulate production, perform contracts of goods supply
- Accounting Department: is responsible for financial monitoring, full and prompt reporting on financial data as required by the Board of Directors, payment of wages to workers, accounting for payment to State budget, funds statistics, stipulation of selling price and management of
finished products in warehouse
- Import - Export Department: is responsible for seeking new customers to expand export markets, making pricing negotiations with customers, delivery procedures, calculating
production costs, contacting carriers to pull Containers to the Company for packing export
goods
Quality Control Department: is responsible for managing quality and food safety of all products produced by the Company, desiging packages, making insurance registration procedures at appropriate authorities (NFIQAVED)
- Warehouse Control Department: is under management of Accounting Department - Import - Export Department; is responsible for importing - exporting frozen seafood products for export as required by the company; keeps the goods in the warehouses at export quality
i _ guợgg
Trang 12PART B: ENHANCING QUALITY MANAGEMENT CAPACITY IN TRA FISH - BASA FISH IN HUNG CA COMPANY LIMITED
CHAPTER I: PROCESSING TECHNOLOGY AND EQUIPMENT 1.1 Processing technology
1.1.1 Raw material
Figure 6 : Pangasius Hypophthalmus
a Biological characteristics of Pangasius Hypophthalmus and Pangasius Bocourti _ Classification
Pangasius Hypophthalmus and Pangasius Bocourti are species of Pangasiidae family distributed
in Mekong River basin, present in all four countries of Laos, Cambodia, Vietnam, Thailand According to the classification system, Pangasius Hypophthalmus and Pangasius Bocourti are
sorted out as follows: Siluriformes Pangasiidae Pangasianodon
Pangasius Hypophthalmus (tra fish), Pangasius Bocourti ((basa fish)
(Sauvage, 1878 cited by Vo Quoc Van, 2004)
Pangasiidae family includes 07 groups of 30 species, there are 16 species in Vietnam, of which 05 species are similar in appearance Typical biological habit is that Pangasius Hypophthalmus
and Pangasius Bocourti are cultured on a large scale in ponds and cages in Mekong Delta _ Morphological characteristics
These two species of fish are rhombic, have a long body and flat sides; their length is four times
longer than their width They do not have scales; their back is grey black and their belly is
silverish; their skin is thick and covered in a viscous layer, their mouth is wide two long
antennae
Pangasius Hypophthalmus can live in all water layers, but usually live in static and flowing water
basins Their absorption organs are skin and air bubble, so they are able to live in rough water
pond, lacking oxygen They are capable of living at high density, living very long in mud on land,
in narrow ponds and lakes, but there should be enough moisture for skin
RR AR AP VRS LOG SEES A SREB SCS SNES EES EST SUR RU raeA HSRR
Trang 13Pangasius Bocourti live mainly in flowing water areas, cultured in cages, large lakes, warm
temperature Pangasius Bocourti need more oxygen than Pangasius Hypophthalmus, if oxygen is
low, they will be asphyxiated because their adaptability to narrow spaces is worse than Pangasius
Hypophthalmus ®, this is a point we should pay attention to during transportation to keep fish
from being dead
_ Nutritional characteristics
Pangasius Bocourti and Pangasius Hypophthalmus are omnivorous, but inclined to eat preys of animal origin and they easily change types of feed At the oocyte stage, they like fresh prey,
ephemeral of size matching their mouths as rotifers, budding, oocyte even eat each other in nursing tanks
In ponds, Pangasius Hypophthalmus adapt to a variety of feeds including organic feed detritus,
bran, vegetables, organic fertilizer, bottom animals, compound feed, animal feces, etc Pangasius
Bocourti also eat different feeds such as bran, vegetables, chipped fish (cooked), they less fight for bait and are bulimic, so they are suitable for culturing in cages
_ Growth characteristics
Pangasius Hypophthalmus in the nature can live over 20 years, and there has been natural Pangasius Hypophthalmus of 18 kg in weight or 1.8 m in length Pangasius Hypophthalmus quickly grow in normal culture condition A Pangasius Hypophthalmus fingerling reaches 1-1.2 kg after one year of culture, 1.5-2 kg after 2 years of culture, 2.5-3.5 kg after 3 years of culture Pangasius Bocourti also gain weight quite rapidly A Pangasius Bocourti finglerling reaches 0.7-
1.3 kg after one year of culture and 2.5 kg after two years if it is cultured in cage
_ Reproductive characteristics
Mature age: male fish is at the second year, female fish is at the third year They do not have external genitalia, it is very difficult to distinguish male, female superficially Maturation period,
the male gonads in development referred to as sperms in male fish, ovaries in female fish Fish
mature season in the nature starts from May to June of lunar month, fish habit is swimming
upstream to migrate to spawning grounds
In terms of artificial breeding, fish may be maturing and spawning sooner (3 months) Re-
spawning is not seen in in the nature, only in artificial condition, fish can spawn 1-2 times a year
In farmers’ fish ponds in Mekong Delta, spawning of Pangasius Hypophthalmus g is rarely seen due to lack of feed, inadequate nutritional composition, short breeding period of 1-2 years
_ Distinction between Pangasius Hypophthalmus and Pangasius Bocourti
Length: Pangasius Hypophthalmus is longer than Pangasius Bocourti
Color: Pangasius Bocourti’s back has lighter blue than Pangasius Hypophthalmus’s, Pangasius Bocourti’s belly is silvery (whiter than Pangasius Hypophthalmus’s belly)
Trang 14
Shape: Pangasius Bocourti’s belly is bigger than Pangasius Hypophthalmus’s because it has much more abdominal fat
(Tra Vinh University, Lecture ‘on fish culture techniques) b Purchase of raw materials
The company's agents directly purchase and transport raw materials to the company for processing Agents assign their staff cages, ponds to collect samples and send them for testing, agree on prices and make purchase contracts (including material declaration, affidavit and antibiotic test results), then transport to the company
c Transportation
Transportation by waterway: mainly transport live fish from An Giang, Dong Thap Means of transport are specialized boats This method is safe and economical The top and end of the boat with holes for water in and out freely to prolong fish lifetime During transportation, attention
should be paid to the following:
Shipping boats must be clean to avoid infecting material Avoid transporting at too high density
During transportation, avoid stopping along the way, if there is any incident, it is obligatory to
find a place with clean water, shade for mooring
Transportation by frozen truck: transport fish from Vung Tau Fish is killed before being put into the truck to avoid hurting each other due to long distance
d Preservation of materials
_ Transportation by boat
When fish are on board, the transport must be done within the day
Make sure the water temperature in the boat is appropriate to keep fish from being dead
The fish should be taken for processing as quickly as possible right after arrival at the port
_ Transportation by truck
Raw material transported in truck with refrigeration systems to preserve materials during transport to the company Refrigeration system in the truck is operated about 4h before the
materials are put in the truck During transport, the refrigeration system is operated by the
transmitter on the truck Fish must also be handled as quickly as possible when arriving at the
company to limit loss because fish has been dead before transport
e Perishing phenomena of raw materials
During transport, materials collide or crash into the hull of boat, truck leading to hemorrhage and accumulation of bruises, detract significantly perceptible In addition, most materials are damaged due to viral infections and parasites, common diseases such as:
Bacterial infections:
Blood bacterial infections caused by Aeromonas
Trang 15
Bacterial infections caused by Pseudomonas (Red spot disease) Blood Bacterial infections caused by Edwardsiella (Edwarsiellosis) Aquatic fungus disease
Cá Tra giống bị xuat huyết
do nhiễm khuẩn (BVL)
Breeding Catfish experienced hemorrhage caused by BVL
Figure 7: Pangasius Hypophthalmus experienced hemorrhage caused by White skin disease (loss of viscosity)
- Diseases caused by parasites:
Parasites and other pests will reduce, or even loss of the safety of food, so during
processing to remove immediately to prevent the possible contamination of harmful microorganisms in a batch Common diseases caused by parasitic infections such as rotifers Disease, Ichthyophthyrius multifiliis, White spot disease (WSD), monogenean,
Lernaea - Anchor Worm, Argulus
Some diseases caused by a lack or im-balancing of nutrients
If feed lacks amino acids, especially the essential amino acids as Arginin, Lysine, Methionine will make fish stunted, growth retardation and disease susceptibility If feed lacks essential
minerals for fish, such lack of selenium (Se), fish will be susceptible to edema Lack of zinc (Zn), fish is easily blurred vision, cataract These vitamins are essential for fish, fish feed lack of
vitamin C, fish is experienced locking gill, spinal deformities, especially in breeding fish of
rearing period Commercial fish without vitamin C may lead to yellow meat, poor quality meat,
low protein (protein) in meat If severe shortage, fish’s resistance will be decreased, disease susceptibility, weak immune systems, fish color is darker, slow-growing fish, weedy If lack of
essential vitamins such as vitamins A, B12, Folic Acid, Thiamine that will make fish anorexia, anemia, skinny If Biotin or Vitamin E is deficient, it will make fish fat and meat yellow
eee eee eae eens eee nN
Trang 16N6
Thịt cá Tra bị vàng đo thiếu đỉnh đưỡng, vitamin (DHCT)
Figure 8: Pangasius Hypophthalmus become yellow due to lack of nutrition, vitamin
(http://www cuulongfeed.com) J Identification and evaluation of quality of raw materials
- Standard materials
Material sources to supply the company are mostly from fish cages in An Giang, Dong Thap, but fish are also bought from Vung Tau and transported by frozen truck Raw materials are purchased through the company's agents, transported by specialized boats Before buying fish, agents must collect samples and send them to appropriate authorities for antibiotics test, if the no antibiotics as well as harmful substances are deteted, then fish are harvested and brought to the company
- Method of checking freshness of raw materials
There are many methods of checking freshness of raw materials, but the company often uses the sensory method to carry out the test The sensory method is based on the following characteristics:
Fish body
Fresh Fish: Hard body, un-bent body when being held at the center of the body, solid meat, elasticity, a dent emerge after the fish body is deeply pressed by a finger
Stale fish: limp body, bent body when being held at the center of the body, soft meat, un- elasticity, a dent remaining after the fish body is deeply pressed by a finger
Examining fish color, viscosity sticking to fish skin
Fresh fish: Outside pink, bright and polish fin, stick on the body, normal shape, transparent mucus, high adhesion of viscosity, natural stinking smell (natural stinking of pond mud)
Stale fish: soft body, bulging belly, loose fins, easy peeling, faded color, darker outer surface,
viscous lump, reduced and dull viscosity, stinking smell, back color usually transferred to brown
or red
Mouth and gills
Fresh fish: closed mouth and gill, gill in dark red or bright pink, no viscosity, no stinking smelly, natural fishy smell
Stale fish: mouth slowly opens, the opened wider the mouth is the more spoilage is, spoiled gill is
LLL Le —
Trang 17dark or pale, gills wide open in the turbid viscosity liquid, sour, rotten smell Fish eye
Fresh Fish: transparent cornea, bright, bulging eyeball, black iris
Stale fish: dim opaque cornea, eyeball recessed below retina, may be broken off, deeply recessed
eyes, white membrane, pale white, black and red irises, iris open, sometimes due to internal movement blood around the eyes pink
Using knife to cut fin and observing cuts:
Fresh fish: bright red cuts, see green trace at cross-section of the fillet, there may be another
color, elasticity, meat close to the bone, the bone still uncertain, especial fishy smell
Stale fish: dark gray cuts, no cross-elasticity, loose meat, close to the bone, bad smell, sometimes stinking smell
Observing abdomen and anus
Fresh fish: normal slim belly, belly bulge is not hard, anal concave rim, white or pale pink fish Stale fish: bulging belly, flabby, distended abdomen when cracked, sometimes green-bellied, red
rim anal, not fresh, convex, if anal rim is completely convex out with dark red, fish is stale
(Source: Publication of Science and Technology Information, Dong Nai, No 01/2006 http://agriviet.com) | Lên — [checking parasites 1.1.2 Processing | |
Figure 9: General processing of frozen fillet Pangasius Hypophthalmus, Pangasius Bocourti
After being transported to the port by boats, raw materials will be taken to the reception area of
NRA ED AOE SS CS I ICES EBSA UES SST US NN Nl a ec once lensanseNonRANSANIANIA
Trang 18raw materials, raw materials will taken straight to the reception area if they are transported by trucks Fish in the reception area will be killed and taken into filleting step, after filleting is finished, then washed, skinned off and transferred to shaping step After being shaped, fish is
transferred to molding step and freezing Finally, packaging and storage are conducted
1.1.3 Main production areas a Worshop 1: Filleting
HN HH y
TH: ,
Figure 10: Filleting process
Figure 11: Production process at filleting step
Trang 19
_ Scaling
To make the statistics on fish amount brought in the company
_ Bleeding
Purpose: To avoid stagnation of blood in the fish's body and make clean white fish muscle while maintaining the beauty and quality of products
Operation: a hand holding the fish head, a hand cutting off the gill and jaw with a specialized,
make the aorta to rupture for blood running out of the body and then push fish into the water tank to wash
_ Washing
Purpose: to clean viscosity, contaminants and microorganisms attached on the fish, wash off
blood
This step consists of two clean water tanks, normal temperature and chlorine concentration of 50
ppm After being bleed, fish is pushed into one of two tanks to wash, remaining tank for rotation, rotation time between two tanks about 8-10 minutes, then take fish and bring to the fillet table
_ Filleting
Reject unused part as organ, bone, head, just take meat of both sides
Operation: Put fish on the cutting board, fish head towards the left side, fish back facing fillet worker; right hand using a knife to make a cut beneath the fin (fish belly), left hand pressing down on the fish body, lean the knife to the right to make a line from mid of the fish body to fish tail, then turn the knife and make a cut to the fish head; use thumb and indicator finger to turn the
fresh cut meat, use the remaining three fingers press the fish belly, lean up the blade to cut along the ribs of the fish, tough and rough cut from the belly to tail throughout, finally separate the fillet
out of the fish body; Fillet table with a fish washing plumbing system, keep water drop to rinse the fish blood and the adhesive substances in the fillet process; turn the rest part of fish body, the back is also towards to the fillet worker, lean the knife to cut along the spine from the dorsal to the tail; Continue to cut the other side of the back, remove the ribs out and cut off the excess meat adhere to the fillet pieces Fish fillet kept in baskets of the fillet worker, then weigh for output
calculation and wash
_ Washing
Clean the remaining fish blood, microorganisms and fat stick on fillet pieces
After the filleting step, the fish is transferred to the washing step At this step, the fillet pieces
washed in static water tanks with chlorine concentration of 30 ppm Washing tank of 1000 liters, the volume of fish for about 12 to 15 kg, change water after 40 washing times and then change to
the skinning off step The skinning off is done by machine
_ Skinning off
Remove skin from the fillet pieces to facilitate the shaping process easier
Fillet pieces is placed on the skin slicing machine, the skin exposed to the machine, the head upward, the tail toward the blade, gently push the fillet pieces for the tail to expose the blade, the blade rotates in a clockwise direction to take away the skin and the fillet pieces is skinned off and
NS EINER AER TE OR EBT SPE SL ENS ASS AT ETNA i NSN NS UE SE Na GS a URES AE INS sh SN ea
Trang 20smooth After filleting step is finished, forward to shaping step to trim
b Worshop 2: Shaping
Figure 12: Process of shaping
Figure 13: Production process at shaping step
_ First Scaling
Making the norm for semi-finished products and the output calculation of workers; after the
skinning step is finished, fillet pieces are forwards to the shaping step, 5kg weight each basket,
weight must be accurate in order not to affect worker’s productivity _ Washing 1
Each worker takes a fish basket to the shaping table Before shaping, fish must be washed in cold water with chlorine concentration of 7ppm, to wash fish cleaner, remove microorganisms and
easily shape _ Shaping
Remove red meat, ribs, remaining skin, blood vein and remove the damaged meat during the process of fillet, cut the tail end to be flat; fish will be shaped upon requests, fish shaped with fat and trimmed fish (fish bone is trimmed)
Operation: put fish on the cutting board, skinning off side facing down, place a knife at an angle
of about 30°, gently trim to separate the fat, bone from the belly, then turn up the fish, lean the
knife to remove the red meat from the back, trim the piece; use the knife tip to make a line on the
nnn nnn ee
Trang 21back, gently trim the blood vein from near the middle of the back up, then use a knife edge at the holder to remove the remaining blood vein until the tail, cut the tail flatly Use ice water during the shaping step to ensure that the temperature is always less than 6°C, to limit the growth of microorganisms
Do not make overtrimming, loss nor for shaped fish is 27%, fatty shaped fish is 22%; After shaping, fillet pieces must be flat, the head, tail are not torn, no red meat, bone and fat left
_ Washing 2
After being shaped, fish will be washed in clean water tank at a temperature of less than 6°C, to wash away the fat meat parts clinging on fish, after being washed, fillet pieces will be more
clean, beautiful
_ Checking out
QC checks whether fat, skin, red meat, bone left or torn rate to assess worker’s productivity, if less than 3 basketballs are completed a day, such working day is considered to be off Workers
shall be reviewed for reward at the end of the year upon their fish basket weight After being shaped, fish will be checked parasite to detect and remove promptly fillet pieces infected with
parasite
Fish is placed on the stage to scan quickly and continuously at a cold temperature, each fish piece is scanned by light to detect parasite, the infected fillet pieces will be removed and treated, the fillet pieces are not infected to be passed to molding step
Notes:
During production process, fish must be kept in cold water and ensure clean according to the directed process
Be sure to use the correct tools so as not to lose fish, keep the cutting board clean wihout blood fat Regularly change washing water, chlorine water, cooled in ice water It is obligatory to be gentle with fillet, don’t put fillet too much in the basket and cover chip ice on fillet layer
c Workshop 3: Molding
Figure 13: Molding Step
Trang 22ÏIIIIIIII
Figure 14: Production process at molding step
_ Preliminary sizing, sorting
Trang 23170-220 220-Up Export to USA : 2-4 4-6 (oz) 6-8 8-10
After sorting, sizing, fillet pieces will be scaled to calculate the weight to put into additive mixing, weighing S5kg/basket Then wash through 3 water tanks: Tank 1 of cold water of 5 ppm chlorine, Tank 2 of 5 ppm chlorine and Tank 3 of clean water, all three tanks at water temperature of less than 5°C After being washed, fillet pieces are stacked, waiting for water running off, then additive mixing
_ Additive mixing
Purpose: to make fillet pieces polished, water retention and weight gain
After running out of water, fillet pieces are put in the spinning tank of 200kg (20 baskets) mixed with 70 liters of water with additives Infusion of 50 liters of water, 2 kg of additives (2 types of
polyphosphate, each 1kg), 0.5kg and 17kg scale ice Spinning time depends on the size of fillet, it takes more time for large size of fillet than small size of fillet The same amount of chemicals, the same amount of fish, but if small size of fillet is mixed with large size of fillet, small size of fillet
will be soft, torn loose, unsatisplant; after the additive mixing step, fillet pieces are polished, weight increased by about 5-10%
If after sizing and sorting are complete, the additive mixing step cannot be done promptly,
preservation by icing for a short time to wait for additive mixing Freezing by dry ice (crushed ice)
Use insulated tank with close lids and drainage holes under the tank bottom, add a grinded ice layer 3-4 cm thick on the bottom, then line a PE layer on the surface of the ice layer, then lay fillet pieces on, one PE layer on one ice layer in turns until filling with a tank The ice layer on the surface is the most thickness
Freezing by wet ice
Less use because it is not highly effective and short preservation, often freeze fish skin in a short time for the trip But also use insulated tank, but put water and ice to form cold water liquid for
preservation
_ Sizing (2"! time)
After the additive mixing step, fillet will be placed on table, workers will make sizing upon requirements This sizing accuracy is high thanks to 2kg quantitative weight to size according to the requirements, suitable sizes Sizing is completed, fillet is transferred to the sorting table for
the 2" sorting, because in each Tl, T2, T3, T4, there are two distinct types After sorting,
different weight is done upon PO and sizing and sorting tag attached to each basket
Le a a ee eee eee eee ae
Trang 24Requirements: avoid wrong tag, proper weight scaling must be made in accordance with requirement, it is not advisable to keep the fillet on molding table
_ Molding
After weighing, fillet is dipped, then place on molding table, the molding is advanced prepared,
cleaned with soap, then wash via water with chlorine, and finally clean water, turn down the mold
to dry Large and small PE bags are washed and dried before laying fish Molding method
For frozen block fillet: Lay a large PE layer on mold and press flat angle close to the mold Fillet
pieces are arranged upside down and not touch each other, depending on the size of fillet pieces
to apply different arrangement methods For large size, arrange 3 pieces, 2 pieces at width and 1 at the remaining width, the head turns into the mold wall Then line a small PE sheet on, turn up
and stroke the PE pieces stick to fillet pieces (chasing air out fillet pieces) and put back The next
layer is PE layer, lay the fillet pieces belly up and lay between the two sides in length, keep a layer of fillet pieces, a PE layer, and lay alternate layers until the basket is empty If small size is
5 pieces, 4 pieces in four corners and 1 in the middle, lay 1 small PE layer above, lay 4 pieces
interspersed gaps in between 4 edges And continue until the basket is empty, after fillet pieces are run off, fold one side of a large PE sheet, lay the tag of sorting, sizing and fold the rest sides of PE sheet
For frozen bulk fillet: Lay a large PE sheet in a similar way, lay each fillet piece separated from
each other, and head back out into the mold wall, also depending on the fillet size, then lay 3
pieces or 5 pieces The fillet layers are separated from each other by small PE layers, about half a basket of fillet, then fold the large PE sheet, then lay another large PE sheet into another mold to _ do the same until the fillet basket is empty, fold one side of PE sheet, then place a tag and fold
another side, turn and put PE down Fillet pieces are placed down from beginning to end
Requirements: It is obligatory to keep fillet pieces flat and neatly, disadvantage can reduce
sensory perception must be hidden inside, fillet pieces must be placed as required and the size tag, use hand to stroke fillet pieces after molding for being polished before setting up another PE
layer
_ Freezing waiting
After completion of molding, if freezing step cannot be immediately done due to lack of freezer or the amount is not enough for a freezing batch, put the molds in the pending freezer at temperature from -1 to 4°C, freezing waiting time £ 4 hours To limit the growth of microorganisms, maintain state and product quality while waiting for freezing
d Workshop 4: Finished product
Trang 25
Figure 15: Production process at finished product step _ Freezing
In order to transfer products from natural condition into freezing in at a high minus temperature
to prevent the activity of microorganisms and extend the preservation time
For freezing exposure, wind freezing: fillet pieces are placed on trolley transported to freezer
Freezer must be clean, start machine prior to lower the temperature down to -10 to -20 °C lay the molds into the freezer in order from bottom to top For wind freezing, put the mold on a large tray and put in the freezer Close freezer and start freezing, about 1.5 times to 2 hours, freezer time
can wind a little longer When the temperature reaches about -40 to -45°C in the freezer, central heat £ -18°C products Check perceptible gain or view product: the product surface hiss, color
white, type in voice heard in, stick it to the freezer
For IQF conveyor: from the steps of molding, trimming and waiting for running out of water,
transfer semi-products to the conveyor, lay semi-products on the conveyor, lay fillet pieces face- down, head towards the direction of the conveyor and tail towards out, fillet pieces are slowly moved into freezing chamber The conveyor is also started up prior to cool down -40 degrees to -
45°C,
_ Molding off - Glazing
Glazing is the process of freezing by | ice water layer on the surface of the product After wetting the surface of the product kept in air, water and get cold from food and crystalize on food surface
to form an ice surface layer adhering on food surface It is not advisable to extend glazing time to
increase the glazing layer, this will de-freeze, but it is advisable to do several times, alternating between each subsequent cooling food The glazing has the following effects:
Trang 26_ Keeping food colder for long preservation Molding off
Frozen block: dip the mold bottom into the water tank continuously then separate the block from
the mold Cover | PE layer and put in packing tank
Frozen bulk: tap the mold on the table surface to separate the mold and mold off fish on the table until the fillet pieces apart, separate PE bag, weigh upon demand, 10% extra weight
For fillet frozen by IQF conveyor, fillet pieces, after going out of the freezing conveyor, are
glazed through the cold water tank then re-frozen and packed Glazing
There are many methods of glazing, but the company applies the method of direct dipping into cold water at a temperature of 0 - 4°C, time depending on the glazing rate of 5%, 10%, 20% or 30% Advantage of the method of direct dipping into cold water is fast and does not require an expensive technology However, there are also weaknesses because the temperature is not fixed and changes over the time of dipping that leads to ice thickness change, making glazing ratio difficult to control, water becomes dirty after a few times of dipping so the company uses tanks with continuous supply of cold water and keeps water overflow
Packing
To isolate products from the external environment, prevent infection, help the shipping process easy, increase the value of products and attract customers and promote products
Upon customer requirements, products are weighed and packed from | - 5 kg, seal by pressing machines and put in carton boxes for a maximum of 10kg, cover the box, use tape to seal the box by straps roping 2 horizontal and 2 vertical bands straightly and firmly, belt color upon customer requirements Outside the box is full of information about product: product name, size, net
weight, production date, expiry date, name and address of the manufacturer, storage conditions
and batch code
Note: If products are not shipped immediately, the products should be temporarily pack and
kept in finished product warehouse, just open and pack by PE bags and shipping boxes on the
shipping day The boxes are marked full details as required by the finished product specification Table 1: Loss norm from processing step to finished product step
Types of} Raw Fillet (kg) Skinning off (kg) |Shaping (kg) Delivery
fish material (extra %)
Trang 27Big fish is less loss than small fish, the process of filleting and shaping is easier for big fish, so there fewer defects; however, loss rate between, big fish and small fish is also nearly equal The
loss rate at the fillet step is the most against other steps because fillet step is to take meat on both
sides, reject head, viscera, bone which accounts for the most of the fish, the loss is about 50% The min loss rate is in the skinning off step because just reject the outer skin, less weight, the loss rate is about 27% in shaping step
1.2 Freezing system
1.2.1 What is freezing?
Freezin is the process of cooling seafood due to heat absorption of the refrigerant to bring the initial temperature of the seafood down to the freezing point
1.2.2 Why to freeze seafood?
Foods at a high temperature under the effect of enzymes of itself and microorganisms will take place the process of changing in substance, leading to being damaged, rotten When the food
temperature is lower down and the said process will be inhibited and restricted, the speed of biochemical reactions will decrease The lower the temperature is, the stronger the resolution will
be As temperature decreases, the activity of living cells is reduced by: _ Cellular structures are shrunk
_ Viscosity of cellular liquid increases
_ Diffusion of water and cell solutes decrease
_ Activity of enzymes in the cells decreases Low temperature inhibits the rate of biochemical
reactions in food
Therefore, decomposition process of the food will be delayed or stopped entirely at low
temperature due to:
_ Activity of the enzyme resolution is suspended
_ The growth of microorganisms is inhibited, the majority of microorganisms stops working
at -3°C + -10°C But at -10°C micrococcuss is still alive but slow growing The mold is better
cold tolerance, up to -15°C mold can only live at moisture of at least 15% When the temperature drops -18°C, water in food can freeze to 86%, meeting the said requirement So the best preserving temperature is from -1 8°C or less for the whole microorganisms and mold
to stop working entirely
1.2.3 Freezing mechanism in frozen food
Because solutes are dissolved in water of food, freezing temperature is lower than 0°C When lowering food temperature down, water in food gradually freezes, depending on their association with cells
When the temperature drops as low as freezing temperature, ice crystals first appear in cell space (the space between the cells) When reaching the freezing point, water in the cell space
ee mam Se GCA A SE SES IS SESE I SES IT A UNSSC AS IE RARER ASSESSES ESEN UR
Trang 28crystallizes and increases solute concentration higher in cells Thus, osmotic pressure increases, the water in the cells tends to space out through the cell, through the cell's semi-permeable screen If the cooling rate is slow, water in cell will make the crystals grow up without the presence of new crystals
If the cooling speed is rapid, crystals will create both outside and inside the cell, ice crystals will be fine and even So if temperature slows down, cells will be dehydrated and ice crystals will be big and pinch and tear the cell membrane, muscle tissue distorted, reduce product quality When
free water is frozen, to combined water, starting from weak combined water to strong combined
water
Trang 29
CHAPTER 2: STATUS OF QUALITY MANAGEMENT 2.1 Quality management in the company
2.1.1 Applied quality standards
a ISO 9000 :
Philosophy of quality (ISO 9000), includes the 4 following main items:
+ Product quality is decided by the management system
+ Do it right from the start, best quality, most economical and lowest cost
+ Give prominence to management by process and make decisions upon facts, data + Tactical action "Prevention is the main task"
The foregoing philosophies are comprehensive and concretized into 8 guidelines for the entire process
of construction and operation of the quality management system + Eight Principles of ISO 9000 ap and complied in Hung Ca:
Principle 1: Customer focus Principle 2: Leadership
Principle 3: Involvement of People
Principle 4: Process Approach
Principle 5: System approach to management Principle 6: Continual Improvement
Principle 7: Factual approach to decision making
Principle 8: Mutually beneficial supplier relationship
b HACCP :
- HACCP is a systematic approach to the identification, evaluation, and control of food safety hazards and first used by Pillsbury and NASA in the 60’s HACCP is a management tool used to protect the
food supply against biological, chemical and physical hazards HACCP is preventive, not reactive and is designed to prevent, eliminate and/or reduce, to an acceptable level, all hazards which have a reasonable likelihood of occurrence
- Seven Principles of HACCP applied and complied in Hung Ca: Conduct a hazard analysis
Determine the critical control points (CCPs) in the process
Establish critical limits
Establish monitoring procedures Establish corrective actions
Establish record-keeping and documentation procedures
Establish verification procedures
NDB
WN
—
HACCP (Hazard Analysis Critical Control Points) HACCP planning process
- Establish HACCP team - Describe product
- Schedule product using methods
- Prepare technological process layout
WED ARE SMHS ARIES ACE REE DE ISN SSAA I ARES OO URINE NL OSA SUC UR YORU 82S LTA ASC AS SCE ASAD ALUSIRODUS i NS eco Cana T ERMINE AH
Trang 30- Check the technological process layout in fact - Analyze hazard and propose preventive measures
- Identify critical control points (CCP) - Establish critical limits for each CCP
- Establish a monitoring program for each CCP - Determine the corrective action
- Establish verification procedures
- Establish procedures for record keeping c SA8000
SA8000 is a system of social accountability standards to improve working conditions for
employees in enterprises, farms or offices developed and supervised by Social Accountability
International (SAI)
SA8000 prescribes accountability in the field of "Safety and Health" for workplace as follows: Safety and health at workplace: The rules of operation, use of machines, equipment,
environmental conditions such as lighting, noise, air pollution, water and soil, temperature at workplace or ventilation air, routine and periodic medical track and care (special regimes for
Jemale employees), labor protection equipment that employees need to be provided to use upon the workplace, the fire protection equipment as well as instructions, expiry date, the issues of evacuation plans and escape in the event of an explosion, chemical safety substance (MSDS) Understand 8 quality control principles of ISO 9000, 7 principles of HACCP, use SA8000
social accountability standard and apply different quality standards, Hung Ca Company Limited has implemented a quality management system consistent with characteristics, requirements and specific activity situation at Hung Ca as well as circumstances, environmental conditions in the fishery production in Dong Thap province of Vietnam 2.1.2 Some criteria for frozen fillet products of Pangasius Hypophthalmus and Pangasius Bocourti a Sensory criterion Table 2: Sensory criterion for frozen fillet Pangasius Hypophthalmus and Pangasius Bocourti Criterion Requirements name
Color Natural White for product features, no strange color
Smell Typical smell for the product, no strange smell Taste Typical taste for the product, no strange taste
Trang 31b Chemical criterion
Table 3: Chemical criterion for frozen fillet Pangasius Hypophthalmus and Pangasius
Bocourti
Criterion name Allowable rate
1 Concentration of total evaporated nitrogen, measured by 25 mg in 100 g of product, not more than
2 Borate concentration, measured by mg in 1 kg of product _| Not allowed
3 Antibiotic residues, measured by mg in 1 kg of product Not allowed
4 Residues of plant protection chemicals, measured by mg Not allowed lkg of product (Fisheries sector standards, 28 BC 117: 1998) c Microbiological Criterion Table 4: Microbiological criteria for frozen fillet Pangasius Hypophthalmus and Pangasius Bocourti
No | Criterion name Rate
| | Total aerobic microorganisms, measured by the amount of colonies 1.000.000 in | gram of product, not more
2 | Total Coliform, measured by the amount of colonies in 1 gram of 200 product, not more
3 | Staphylococus aureus, measured by the amount of colonies in 1 100
gram of product, not more
4 | E coli, measured by colonies in 1 gram of product Not allowed 5 | Salmonella, measured by the amount of colonies in 25g of Not allowed
product
6 | Vibrio cholera, measured by the amount of colonies in 25g of Not allowed
product
(Fisheries sector standards, 28 BC 117: 1998) 2.2 Food hygiene and safety in Pangasius Bocourti processing
2.2.1 Water supply
a Requirement
Water contacting food or food surface used to make ice water must ensure safety and hygience and meet drinking water standards
b Layout of water treatment system
Trang 32
Spring water Ỳ Mist sprayer Vv Raw water reservoir |- Chlorine Ỳ Coarse filtration system r Softening system \ Fine filtration system Ỳ Ultraviolet sterilization Vv Clean water reservoir Ỳ High-pressure tank r Water for use
Figure 16: Supplied water treatment system
Water source: Use 4 groundwater wells, depth of 160m or more, supply capacity of 50m*/h After the treatment process, water meets safe hygienic standard 28 TCN 130 1998 TC
1329/2002/BYT/QD, 98/83/EC dated November 3rd, 1998 periodically tested Chemistry,
Physics, Microbiology by management agency
The treatment system capacity is relatively large, including a redundant system, motors, generators, so the plant’s water source is guaranteed for production
AMARANTE AEE ELS RIC DATS SMATTERING SSA Luce
Trang 33The systems of clean water supply and untreated water are separate
Water treatment system is as follows: _ Mist sprayer
Water from the wells is pumped to the mist sprayer, the oxygen in the air to oxidation of Fe?” to
Fe’ precipitates and some multivalent metals are oxidized and precipitated here At the same time a number of unpleasant odors are also removed at this step, then the water is put into the sedimentation tank
The process of pumping from wells to mist sprayer with pump quantitative of Chlorine,
metabolism Fe** to Fe** occurs faster, besides chlorine also has an effect of sterilization by using oxidizing agents of Chlorine destroying cell membranes of microorganisms in the water
_ Coarse filtration system
After settling in the sedimentation tank, water is pumped through the filtration system, which acts to retain precipitation and precipitation cotton buds crystallization process precipitated by
creating and prevent sediment [1m size, so that the water reaches the acceptable purity After
going through the coarse filtration equipment, iron in water fell by 0.3 mg / I At the same time the part helps the following part work better, the system equipped with a back relief valve to wash & filter
_ Softening system
After going the softening equipment, the iron content is at allowable standards of 0.1 - 0.2 mg/l Hardness also meets standard in seafood processing This system reconstitutes with 200 | of NaCl 5% for filter cleaning
_ Fine filtration system
Preventing residues 1L , bringing water to the allowable purity _ Sterilization with ultraviolet ray (UV ray)
Wavelength of 252 nm, 99.9% sterilization efficiency, lifespan of 8000 continuous hours
Treated water goes through the ultraviolet light system to sterilize, then goes into the reservoir and then pumped to the water fountain to put into production
iii Required operations
_ Get water samples for microbiological test once a month, testing physics, chemistry every
6 months at the appropriate authority
Trang 34_ For filtration at the pressure meter of 1.8 - 2 kg/cm *, then proceed to wash & filter _ Fine filtration at pressure meter of 2 kg / cm >, then proceed to replace filter
_ Softeners reconstitute after 14 days
_ Pipeline system of water distribution for production is sterilized every month / time
Trang 35Wastewater from the production workshop is gathered to the processing system according to its separate pipeline Water is passed through raw waste strain to separate solids of large size and
flow into the collection tank, then pumped to the fatting off tank to separate grease out of the
water Next, wastewater is brought into balancing tank to regulate flow and components of BOD,
COD of waste water Supplied by oxygen from the air blowers, waste water is mixed that helps
suspended solids not settle in the tank, avoid anaerobic fermentation and reduce a portion of BOD, COD concentration in the wastewater
In the flotation tank, the tiny fat remaining in the wastewater is separated The solids in the water adhesive with tiny bubbles that make up the cotton residue, gradually increased in size increasing
performance to separate solid-liquid In the pressure tank of the flotation tank, water saturation at
pressure 3-4 atm, when put into the flotation device at atmospheric pressure, gas supersaturated
will separate from water forming micro bubble 30(1m size 20 The bubbles will stick with cotton
residue formed earlier, reducing specific weight and pulling onto the surface of the flotation device Here, they are collected by a sediment collection device to be taken out Some residues of large density do not float on the surface, but settle to the bottom and taken by a sludge settler to the sludge thickener Part of clear water continues to be taken to biological tank for biological
treatment
In the process of biological treatment, organic contaminants continue to be handled by the suspended growth of microorganisms, they use organic matters in the water as a source of energy to survive and thrive From the biological tank, wastewater flows into the sedimentation tank
The process of activated sludge and treated wastewater separation takes place here After being
clarified, water continues to be finally handled in the sterilization tank After being sterilized,
wastewater meets TCVN B 5945 - 1995 standard and is discharged to Hau River Table 5: Description of wastewater characteristics No | Name of criteron Unit Synthesis 1 | Flow MÔ 400 2 |COD Mgi] 1217.3 3 |BODs Mg/1 917.5 4 |SS Mgi] 1020
5_ | Vegetable oil and grease Mgi] 39.4 6 | Total phosph otal phosphorus Mg/I g 228
Trang 36
6 | Total Phosphate Mgi] 0
7 | Amount of oil & grease Mgil 0 8 | Coliform MPN/100ml 0 00
9 |pH 5.5 -9
2.2.3 Industrial hygiene, occupational safety _Cleaning machines and equipment
Machines and equipment are cleaned before and after use or when transferred to other production items All machines and equipment for production are repaired, checked and cleaned regularly
Freezer is cleaned by spraying water after every taking products from freezer, cold stores or containers are cleaned periodically
_ Cleaning processing tools
Tools for production, such as wash basin, basket, table, cut, scissors are cleaned before and after processing, cleaning is done through the following steps: wash with clean water, wash with
soap, wash with chlorine and finally re-wash with clean water for removal of chlorine _ Personal hygience and labor protection
All officers and employees, visitors, supervisors of processed goods should wear labor
protection when entering into the workshop
People with infectious diseases, limb wounds, pimples are not permitted to enter into the workshop Absolutely not bring jewelry, watches, and do not nourish long fingernails Do not
polish nails, smoke, talk and spit in production area
When entering into the workshop, workers go through the tank containing chlorine solution to dip their boots and wash hands as stipulated:
Dip hands from the elbow downwards in water
Apply soap on hands, rub both arms, hands several times Wash hands with clean water until soap is off
Dry hands with a towel
At the beginning and the end of the working shift, workers are required to do personal hygiene Coveralls and boots are cleaned with soap and water after the production hour Gloves are
cleaned 2 hours / time, when moving from the step to other step, replace gloves to avoid cross
contamination
Workers should take off labor protection devices when going to toilet and wash hands as stipulated after returning Workers should wear gloves, overalls suitable to each step Do not
wear labor protection devices out of the company _ Environment
Trang 37
The company equips containers of scrap, waste in the production The containers of scrap, waste have lids
By-products (fish heads, fish bones, fish skin .) after being moved out of the treatment area are kept in the by-product area and quickly transported, sold to farmers as animal feed, or sold to the feed processing plant
For solid waste: The company has contracts with urban construction companies for collection PE bags are collected and recycled at the company
_ Occupational safety
Freezing chamber and storage warehouse have low temperature, so they are equipped with warm clothes, hats and gloves to anti the cold, and avoid cold burn Ensuring the health of the mothers
after birth, pregnant women only working in office hours, no overtime and maternity leave regime as prescribed Workers have medical check-up once a year The company has a medical team on duty during working hours, which is fully equipped with beds and medicines to cater for workers
The outer parts of the stages of equipment, gear belt barriers shielding the main areas prone to accidents equipped with lights For safe use of machines, there are manuals at the machine place,
complicated machines are operated by specialized section Always keep a safe distance between
machines and workers
Arrange appropriate number of workers in each production area to ensure a safe distance between workers in production process
There are also measures to prevent noise in production, reduce noise at places of generation and transmission, use the vehicle for personal protection to avoid fatigue, effects on hearing, startle, earache
The boot dipping tanks are arranged in the entrance area of production and frequent water
changes Lavatory faucets and downspouts meet the needs of workers during peak hours, taps are controlled by foot, with dry hand towel shelf troughs, in addition to drinking water bottles for
workers
Toilets are located far away from the production, number of toilet rooms in accordance with the number of workers, the walls are painted with waterproof paint, trash bins are opened and closed
by foot
Trang 38
CHAPTER 3:
PROPOSAL OF NEW MEASURES TO IMPROVE QUALITY MANAGEMENT EFFICIENCY IN PLANT
3.1 General comment and assessment of current quality management at the plant
3.1.1 Strengths
The quality management system ISO 9001 has been implemented and other quality standards (such
as DL 126 - HACCP, HALAL, BRC, IFS, ISO 22000, ISO 9001, BMP, GLOBAL GAP, ASC) have
been complied at the request of customers and markets 3.1.2 Weaknesses
- Quality tools to measure the process capability, effectiveness evaluation of each step in the production process have not been applied
- Some sanitary problems in production stipulated under guidance of the Pre-Requisite programs HACCP (such as GMP and SSOP) need to be improved
3.1.3 Causes of weaknesses
Proper attention has not been paid to guidance and advanced training on statistical tools in Hung Ca Company, so they are not applied
3.2 Proposals of measures to improve quality management
Establish improvement under the following 5 groups of measures: - Group of quality management at every step of the process
- Group of cost reduction in processing
- Group of on-time delivery capacity enhancement
- Group of food safety and hygiene
- Group of professional ethics improvement
There are 12 detected problems in the review, evaluation process in 2014 and the improvement is proposed by this report preparer according to contents presented in the following sections
1 Detected problem: Hand washing process at the plant 1.1 Status
The plant has:
- Notified the handwashing process which consists of 5 steps which are drawn on the plastic board on the wall at the entrance to the production area
- Installed 6 handwashing faucets controlled by foot, water flow into downspouts - Hand wash soap is liquid water in 6 faucet bottles
- Water valve is located in a convenient place so that the washer can easily turn off the faucet without touching Savon or valve
For dry hands after washing, use tissue and reject immediately after use 1.2 Risk Identification
- Dirt on the plastic board is the inhabitation for all kinds of microorganisms (bacteria, parasites) - Employees can ignore or distract themselves by washing hands without anyone monitoring;
- Hand washing process does not detail hand washing action;
- Hand washing process does not use antiseptic;
- Hand washing procedure does not specify cutting nails, fake nails,
1.3 Proposal for improvement to reduce risk
Trang 39- Compliance with hygiene regulations are monitored regularly;
- Improve handwashing quality
b) Improvement measures:
- Clean the plastic Board of handwashing procedures weekly, the board is dirty;
- Install the surveillance camera at this site to anyone who goes through it will be noted that they
wear protective clothing, boots, gloves, masks, hats and wash hands properly
- Improve handwashing under | additional process and equip the necessary facilities for hand washing which will be presented below
c) Hand washing process is improved as follows:
(i) Interpretation of improved regulations is as follows:
- Wash hands in accordance with steps to eliminate microorganisms on hands because the warm moist environment inside the glove can stimulate the growth of microorganisms available on hand if washing hands are not carefull to contaminate for semi-finished or finished products
- Time for hand washing is about 3 minutes
- Use soap to kill bacteria (such as Lifebuoy soap a brand available on the market that is committed to the protection from bacteria 99.9%) or antiseptic liquid water
- It is obligatory to keep short nails, no nail polish, don’t wear artificial nails (ii) Time for hand washing:
Except for the case of an emergency, workers should wash their hands The appropriate time for hand washing might be "before" and "after" the facts as presented below before entering production areas:
BEFORE:
1 Before direct contact with all the tools and all materials and semi-finished products;
2 Before a new operation in different steps in production process to prevent cross- contamination of finished products or processes in different positions in the production area (for
example, when moving from Filleting step which is likely to contaminate cleaning position of fillet in
the sizing and sorting step); 3 Before wearing gloves;
4 Before eating;
5 Before leaving the plant to home
AFTER:
1 After arriving at the plant;
2 After exposing to work tools, supplies and semi-finished products;
3 After exposing to body fluids, mucous membranes, skin, fish or any part of the fish;
4 After exposing to instruments that are likely to be infected with a large number of bacteria, parasites, microorganisms generally; including measurement devices in the production area or store tanks of fish by-products;
5 After exposing to fixed objects in the environment surrounding the production; 6 After removing gloves;
7 After using toilet
(iii) Flowchart of improved handwashing process:
xa =~ Step 1: Remove jewelry (rings, watches, bracelets ) on the hand and wrist
Trang 40H_ Step 3: Clean under nails with files and brushes
|
C} Step4: Puthands on the elbows Use soap or antiseptic water Start from the fingers
of a hand, wash in circles down to elbow to make sure all surfaces clean Wash the other hand in the same way
Hi Step5: Run water into cach hand to separate water from fingertips to elbow
wy
\ / ian
a y [ „ TÀI
— Step6: Use sterilized tissue, wipe your fingers, hands and then arms Use different
NI “© side of tissue for each hand Ow N 7 | fA — —“Step7: Keep your hands obove the waist with fingers putting upward Do not touch ` ae | 3 | x} /⁄ anything else before wearing gloves `" / † ⁄
d) Equipped with necessary facilities for hand washing
(i) Besides the existing facilities at the plant (tap water, soap, tissues to dry hands) equipped with sanding, clean nail brush set available at the appropriate location in the washing areas
(ii) Providing soap and hand cleanser as directed below:
- Soap is regular (neutral briquettes, or liquid): Soap-esterified fatty acid and sodium or potassium hydroxide helps take away the current strains of microorganisms on the skin loose grip The hand washing solution can be used as Pose liquid soap
- Sterilizing soap (cake form or liquid form) contain antiseptic soap Para -chloro xytenol -
meta often used as the main active ingredient of antiseptic soaps
- Antiseptic hand wash solution contains 2% - 4% chlorhexidine; or 5% - 7% iodine
providone; or 1% triclosan The type of antiseptic hand cleanser recommended using Microshield 2% or 4%
- Antiseptic liquid: May contain one of the following chemicals: Alcohol, chlorhexidine, chlorine, hexachlorophene, iodine, Para chloro meta xylenol, grade ammonium compounds 4 and substance associated Triclosan and skin lotions Solution container labeled hand lotions, wall positioned in users
- Ifthere is no liquid soap, bar of soap to be placed on a soap box with a small hole down to the water after use Cut soap into small pieces rather than regular soap, to prevent the
growth of microorganisms (iii) Drying hands
- Must reject used tissue Use a tissue or disposable cotton fiber towel, daily washing, with a
clean box and place in a convenient location