Assignment 01

HACCP Plan for Tea Cake Production

Process

 M.R.C.S Wimalasena
 Uva Wellassa University,Sri Lanka

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  Content

Page No.
1. Introduction 3
2. Process flow diagram 4
3. Suitable Sanitizers 5
4. Personnel Hygiene 6
5. HACCP Plan 7
6. HACCP Determination 10

 Introduction

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Tea is a major cultivation crop in Sri Lanka, although there many value added tea food
products, Tea cake is not given much of consideration. This is mostly because tea cake is not
a blooming industry in Sri Lanka`s import and export market. So there is lack of attention
given in regard food safety related to tea cake industry, and also in order to protect and
maintain current brand name Ceylon Tea, we produced this HACCP report with
consideration of tea cake industry. In this report we discuss all main issues related to this
particular industry, food safety measures, sanitizers and personnel hygiene. In the current
market trend food safety is considered with high regards. In order to survive the market and
deliver safe food products, the HACCP plans and ISO standards should be followed. HACCP
is a management system in which food safety is addressed through the analysis and control of
biological, chemical, and physical hazards from raw material production, procurement and
handling, to manufacturing, distribution and consumption of the finished product. For
successful implementation of a HACCP plan, management must be strongly committed to the
HACCP concept. A firm commitment to HACCP by top management provides company
employees with a sense of the importance of producing safe food. HACCP is designed for
use in all segments of the food industry from growing, harvesting, processing, manufacturing,
distributing, and merchandising to preparing food for consumption. In order to design a
perfect HACCP we should familiarized with the process flow of the specific food we
produce.

 Process Flow Diagram

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 Procurement and Quality
Inspection of Raw Materials

Storage of Raw Materials

Weighing and Pre-Preparation of

Raw Materials as per Standard
Recipe

Batter making

Batter Scaling Deposition and

Leveling into Moulds

Baking

Cool at Ambient Temperature

Slicing and Packing

Storage

Distribution

 Suitable Sanitizers

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There are numerous commercial products available for disinfecting and sanitizing surfaces in
food premises, such as restaurants or processing plants. As the intended use and toxicological
risks are different, disinfectants used on non-food contact surfaces (e.g., environmental
surfaces, medical devices) are regulated differently than those used on food contact surfaces.
Labelling should always be read before using disinfectants, as they specify the intended uses
that are appropriate for the product. Water is involved in food process in various stages from
washing to soaking then involved in either directly food production as an ingredient or in
some in direct manner to mix or bake or steam. It is also important for washing and sanitation
operations. Water in food industry must conform to ISO 3025 and ISO 10500 standards.

1. Calcium and sodium hypochlorite’s

Suitable for cleaning gutters and drainage of the facility and floor cleaning of toilettes and
other areas where cake processing is not done (labourer rooms, common areas).
Concentration is 50 to 500 ppm typical although 200 ppm is effective for numerous surfaces,
800 ppm is suggested for porous areas. Avoid contact with corrosive surfaces.

2. Quaternary ammonium compounds

Effective against Salmonella and E. coli. Concentration is 200 to 1.000 ppm typical generally
used at 200 ppm.Exellent for cleaning storage room floors where bacterial growth is high.
Suitable for cleaning corrosive surfaces like metal racks where goods are stored

3. Iodophors

Effective against Salmonella and E. coli. Concentration 6.5 to 75 ppm is typical. Good for
cleaning kitchen ware, mixtures, ovens all the food contacting metal surfaces.

The selection of a specific detergent and of a specific disinfectant will depend on the
material/products being conveyed. The recommendation of the manufacturer of the detergent
and of the disinfectant should be strictly followed especially regarding concentration levels.
After the cleaning of the hose with detergent followed by the rinse of it with potable water,
the hose must be sterilized either with steam or with chemical solution.

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  Personal Hygiene

Personal Hygiene is an important and key aspect to bakery in relation to food safety. Being
labour oriented process it is of utmost importance to maintain personal hygiene. Even a
healthy person harbours and is a carrier of host of micro-organisms. To eliminate and reduce
the possibility of contamination the following steps need to be taken

1. Wearing clean clothing or a uniform preferably cotton

2. Hair restrictions like beard net or a hair cap, scarf to restrict contamination due to
hair fall
3. Strategic placing of hand washing stations and foot dips to reduce microbial load
4. Restriction on use of rings, bracelets and necklaces to avoid contamination.
Implementation of jewellery policy will help
5. Food handlers suffering from infectious diseases discouraged in production areas
6. Personal habits like chewing or eating food in production, scratching nose, hair
should be avoided
7. Food handlers shall always wash their hands with soap and clean potable water,
disinfect their hands and then dry with hand drier or clean cloth towel or disposable
paper
8. Food handlers shall always wash their hands at the beginning of food handling
activities immediately after handling raw food or any contaminated material, tools,
equipment or work surface, where this could result in contamination of other food
items or after using the toilet
9. The food handlers should trim their nails and hair periodically.
10. Street shoes inside the food preparation area should not be worn while handling &
preparing food. Food handlers should not handle soiled currency notes/cards to
avoid cross contamination

 HACCP Plan

Food hazards are the factors, which are the biggest threat to food safety. A hazard is defined
as: a biological, chemical, or physical agent in a food, or condition of a food, with the
potential to cause an adverse health effect.

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 1. Physical Contaminants

Any foreign object (inanimate) found in the food or a naturally occurring object (bone in
fillet), that poses a hazard is called a 'Physical Contamination or Hazard'.

 Metal
 Stones
 Wood Plastic
 Parts of pests
 Insulation material
 Bone
 Fruit pits
 Glass and Hair
2. Chemical Contaminants

Chemical hazards are in two categories: naturally occurring poisons and chemicals or
deleterious substances. The first group covers natural constituents of foods that are not the
result of environmental, agricultural, industrial or other contamination. Examples are
aflatoxins and shellfish poisons. The second group covers poisonous chemicals or
deleterious substances which are intentionally or unintentionally added to foods at some
point in the food chain. This group of chemicals can include pesticides and fungicides and
well as lubricants and cleaners

 Plasticisers and packaging migration

 Chemical residues
 pesticides, cleaning fluids
 Toxic metals; Lead and cadmium
 Food chemicals; preservatives
 processing aids
 polychlorinated
 biphenyls (PCBs),
 printing inks
3. Biological contaminants

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Biological contaminants are the living organisms, or substances produced by organisms, that
pose a threat to human health. They are a major concern in food processing because they
cause most food borne illness outbreaks.

 Macro biological – rats, birds

 Micro biological – insects like cockroaches.
 Pathogenic Bacteria – E-coli , Salmonella spp., Bacillus cereus, Staphylococcus

We assume that the food processing have certain aspects regarding food safety before
designing the HACCP plan. We discuss those aspects below in order to implement the best
possible plan for the Tea Cake Processing plant.

 Location & surrounding

Location of Bakery Establishment shall be located away from environmentally polluted areas
and industrial activities which produce disagreeable or obnoxious odour, fumes, excessive
soot, dust, smoke, chemical or biological emissions and pollutants, and which pose a serious
threat of contaminating food; areas subject to flooding; areas prone to infestations by pests;
and areas where wastes, either solid or liquid, cannot be removed effectively.

 Equipment

The equipment’s shall be such located, designed and fabricated so that they permits necessary
maintenance and cleaning functions as per its intended use and facilitates good hygiene
practices inside the premise including monitoring and audit. Equipment and containers that
come in contact with food and used for food handling, storage, preparation, processing,
packaging and serving shall be made of corrosion free materials, which do not impart any
toxicity to the food material. Equipment and utensils used in the preparation of food shall be
appropriately labelled, kept at all times in good order and repair and in a clean and sanitary
condition, and shall not be used for any other purpose. Proper Procedures should be available
for handling each equipment like Ovens, Mixers, and Proofers etc. Equipment shall be such
located, designed and fabricated so that it permits necessary maintenance and cleaning
functions as per its intended use and facilitates good hygiene practices inside the premise
including monitoring and audit. Appropriate facilities for the cleaning and disinfecting of
equipment’s and instruments especially cleaning in place system to be adopted.

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 Water Supply

Only potable water in processing and cooking, food handling, washing shall be used and it
shall be tested according to ISO 10500 requirements. The storage tanks shall be cleaned
periodically & records shall be maintained. The non-potable water can be used for cleaning
of equipment not coming in contact with food, food steam production, and firefighting &
refrigeration equipment. The non-potable water pipes shall prevent the use of this water for
contamination of food material and shall be clearly distinguished from those in use for
potable water by using colour coding systems.

 Procurement of raw material

All raw materials and food ingredients should be procured from approved suppliers and must
conform to FAO Regulations. As per Condition of license, every manufacturer, distributor or
dealer selling an article of food to a vendor shall give either separately or in the bill, cash
memo or label a warranty in Form.

 Storage of raw material

After receiving and accepting the raw material, there comes the need of storage. The storage
facilities shall be designed and constructed to avoid cross - contamination during storage,
permit adequate maintenance and cleaning and shall avoid pest access and accumulation.
Cold Storage facility shall be provided for food that requires being stored below 5°C.

 Cleaning and Sanitation

Use of cleaning and sanitation program will be helpful to maintain the cleanliness and
hygiene in the bakery. This program can indicate the areas, and equipment to be cleaned at
set frequencies and the method of cleaning and sanitizing. This is helpful from the point of
Good Manufacturing Practices (GMP). Formulation of Standard Sanitary Operating
Procedures for the areas and equipment will provide standardisation to the bakery unit.
Dusting and mixing operations in a bakery tend to create a thin mist or dust of flour all over
the manufacturing premises, this leads to build up and microbial proliferation. Also proper
sanitation of fermentation chamber or premise will help to eliminate bad microbes and
undesirable growth in the product. Cleaning of burnt product, soot from the over

 HACCP Determination

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 Stage Potential Hazard CCP Decision CCP Critical Preventive Correcti
Hazard Descriptio Tree (Y/N) limits Measures ve
type n Actions
Q Q Q Q
1 2 3 4
1.Procureme Biologica Microbial Y N N N Dry Check control
nt and l contaminat storage cleanliness carried
Quality ion through at room of transport out at
Inspection of damaged tempera vehicles the rece
Raw packaging. ture and personnel. ption for
Materials Incorrect (25-30 Control transpor
hygiene C) of integrity t
(Room practices Rh = of the packaging vehicles
Temp.) 90-92% , labelling and pac
Time and shelf life. k- age
less HACCP integrity
than 1 certificate from
month the supplier.
Maintain
facilities
and equipment
for the operation
properly
sanitized

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 Physical Contamina Y N N N Antibiot HACCP control
tion ic certificate from carried
by foreign residue the sup- plier. out at
objects should Control the rece
(hair, ne nil of package ption for
insects) integrity transpor
through t
Damaged vehicles
packaging and pac
k- age
integrity
,

Reception Biologica Microbial Y N N N Storage Control Returnin

of raw l contaminat at (0-10 the product g or
materials ion C) temperature. removal
(refrigerated and multi- Check transport of
between 0 plication Rh = vehicles hygiene damage
and 10ºC) due to 90-92% and personal d goods,
Inadequate Time hygiene. avoid
transport less Control- ling contami
temperatur than 1 the integrity nation
e. Incorrect month of the packaging of
hygiene , labelling damage
practices and shelf life. d goods
Cracked HACCP with,
/broken certificate from undama
eggs the supplier. ged
should Keep facilities, goods.
be nil equipment
and utensils for
Antibiot the operation
ic properly
residue sanitized.
should Perform task
ne nil in a fast,
hygienic
and seamless

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 way
2. Storage of Biologica Microbial Y N N N Dry Pest control Compan
Raw l contaminat storage plan. Keep y Pest
Materials ion at room containers Control
(Room (Salmonell tempera closed Plan
Temp.) a, ture and secured and the 
Staphyloco (25-30 in proper place. fulfilme
ccus C) Compliance with nt
aurous Rh = good personal of good
and Escher 90-92% hygiene hygiene
ichia coli; Time practices. Keep practice
Pests – less facilities, s
Leptospira than 1 equipment
month and utensils for
Antibiot the operation
ic properly
residue sanitized.
should Perform FIFO
ne nil (first in, first out)
stock rotation

Physical Contamina Y N N N Keep containers control

tion securely closed carried
by foreign and placed out
objects in proper during
(hair, location. storage
decorations Controlling and com
, pieces the integrity pliance
of pack- of pack- aging. with
aging, Compliance with good
insects) good personal hygiene
hygiene practice
practices. s
Storage Biologica Microbial Y N N N Storage Control storage Verifyin
of raw l contaminat at (0-10 temperature. g
materials ion due to C) Keep containers complia
(refrigerated storage securely closed nce with
between 0 temperatur Rh = and placed good
and 10 ºC) e 90-92% in proper manufac
Time location. Keep turing
less facilities, and hygi
than 1 equipment ene
month and utensils for practice
the operation s

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 Cracked properly
/broken sanitized
eggs
should
be nil

Antibiot
ic
residue
should
ne nil
3. Weighing Biologica Microbial Y N N N Holding Perform the task Verifyin
and Pre- l contaminat Time quickly, g
Preparation ion less hygienically complia
of Raw (Salmonell than and without nce with
Materials as a, 25min, interruptions. good
per Standard Staphyloco Temper Compliance with hygiene
Recipe ccus aureus ature good personal practice
and Escher 20- 25 hygiene s
4.Batter ichia coli) C practices. Keep
making(mixi facilities,
ng Beating equipment
ingredients) (mediu and utensils for
m the operation
speed, properly
20 sanitized
Physical Contamina Y Y Y minutes Good personal Standar
tion ) hygiene d
by foreign practices. Visual sieving
objects inspection of salt of
(hair, material
decorations s
, pieces through
of packagi 32u
ng, stones mesh
– salt)
Chemical Detergent Y N Y N Y Keep the sites, Verifyin
residue equipment g
and mixtures for complia
the operation nce with
properly good
sanitized, hygiene
checking practice
kitchenware and s

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 mixtures
constantly
before batter
making.
5. Batter Biologica Microbial Y N N N Temper Perform the task Verifyin
Scaling l contaminat ature quickly, g
Deposition ion 20- 25 hygienically complia
and Levelling (Salmonell C and without nce with
into Moulds a, Rh = interruptions. good
Staphyloco 90-92% Compliance with hygiene
ccus aureus good personal practice
and Escher hygiene s
ichia coli) practices. Keep
facilities,
equipment
and utensils for
the operation
properly
sanitized
Physical Contamina Y N N N Compliance with Verifyin
tion good personal g
by foreign hygiene complia
objects practices nce with
(hair, good
decorations hygiene
) practice
s

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 6.Baking Biologica Microbial Y N Y N Y 10–12 Compliance with Constan
l contaminat minutes good personal t
ion at 200 – hygiene monitori
(Salmonell 220ºC practices. Meet ng of
a, binomial time / internal
Staphyloco temperature set temperat
ccus aureus ure of
and Escher ovens ,
ichia coli on daily
basis to
avoid
low
temperat
ure , if
temperat
ure is
below
standard
level
replace
the oven
coils
7.Cooling at Biologica Microbial Y N Y N Y 25-30C Compliance with Verifyin
ambient l contaminat good personal g
temperature ion hygiene complia
(Staphyloc practices. Keep nce with
occus facilities, good
aureus) equipment hygiene
and utensils for practice
the operation s
properly
sanitized

8.Slicing and Biologica Microbial Y N Y N Y Holding Compliance with Verifyin

Packaging l contaminat Time good personal g
ion less hygiene complia
(Salmonell than practices. nce with

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 a, 20min, Perform the task good
Staphyloco quickly, hygiene
ccus aureus Temper hygienically practice
and Escher ature20- and without s
ichia coli) 25C interruptions.
Keep facilities,
equipment and
mixtures for
the operation
properly
sanitized
Physical Physical: Y N Y N Y Compliance with Verifyin
Contamina good personal g
tion hygiene complia
by foreign practices. nce with
objects Perform the task good
(hair, quickly, hygiene
decoration) hygienically practice
and without
interruptions
Chemical Detergent Y N Y N Y Keep facilities, Verifyin
residue, equipment g good
migration and utensils for hygiene
of undesira the operation practice
ble properly s
substances sanitized. and the 
into Confirm adequac
the food suitability y
of the packaging of the pa
material for food ckaging
use material
to food
use

9.Storage Biologica Microbial Y Y Y tempera Compliance with Verifyin

l contaminat ture 25- good personal g
ion 30C for hygiene complia
(Salmonell a practices. nce with

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 a, maximu Perform the task good
Staphyloco m 5-7 quickly, hygiene
ccus aureus days hygienically practice
and Escher and without s
ichia coli) interruptions.
Pests rats Keep facilities,
and equipment and
cockroache mixtures for
s the operation
properly
sanitized
Physical Contamina Y N Y N Y Compliance with Verifyin
tion good personal g
through hygiene complia
human hair practices. nce with
, nails etc. Perform the task good
quickly, hygiene
hygienically practice
and without
interruptions
10.Distributi Biologica Microbial Y N N N Temper Compliance with Verify
on l contaminat ature 25 good personal all
ion – 30 C hygiene product
(Salmonell practices. Protect packagi
a, the product from ng’s are
Staphyloco direct contact intact
ccus aureus with customers and
and Escher and environment well-
ichia coli) al sealed
contamination.
Physical Contamina Y N N N Compliance with Verifyin
tion good personal g
by foreign hygiene complia
matter as practices. Protect nce with
like sand , the product from good
dust and direct contact hygiene
soot with customers practice
and environment s
al contamination
In conclusion, HACCP system is very useful tool in food organizations. HACCP is a system
focus on thing involved with food products details of the food process and also identifies the
awareness of safety problem. Not only that, it requires commitment of the management, the
employees in the organisation, and further monitoring for all kind of food process. Besides

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that, HACCP is a priority to control the hazards in food process. By controlling the food
production to cause hazards, HACCP system has to be followed in order to provide safe food
for the consumer. Every food industry should have this system to analyse the hazards and to
overcome the hazards and provide safe food for consumer so that consumer have confident to
consumer, also it will give many benefits to food producers as well as labourers.

 Reference
1. MARQUES, N., MATIAS, J., TEIXEIRA, R. AND BROJO, F.
Implementation of Hazard Analysis Critical Control Points (HACCP) in a SME: Case
Study of a Bakery (Marques et al., 2012)
Marques, N., Matias, J., Teixeira, R. and Brojo, F. (2012). Implementation of Hazard
Analysis Critical Control Points (HACCP) in a SME: Case Study of a Bakery. Polish
Journal of Food and Nutrition Sciences, 62(4), pp.215-227.Anon, (2019). Online
Available at:
https://www.researchgate.net/publication/271314562_Implementation_of_Hazard_Anal
ysis_Critical_Control_Points_HACCP_in_a_SME_Case_Study_of_a_Bakery
[Accessed 1 Jul. 2019].
2. U.S. Food and Drug Administration. (2019). HACCP Principles & Application
Guidelines. [online] Available at:
https://www.fda.gov/food/hazard-analysis-critical-control-point-haccp/haccp-principles-
application-guidelines [Accessed 1 Jul. 2019].
3. Ncceh.ca. (2019). [online] Available at:
http://www.ncceh.ca/sites/default/files/Food_Contact_Surface_Sanitizers_Aug_2011.pd
f [Accessed 1 Jul. 2019].

 Group Members

Name Registration Number

1. J.A.P.N Alwis UWU/TEA/15/002
2. M.A.S Gunathilake UWU/TEA/15/010

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 3. H.P.H.D Premsasiri UWU/TEA/15/024
4. M.R.C.S Wimalasena UWU/TEA/15/039
5. K.M.T Madushanka UWU/TEA/15/046

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