Orang-e-nick

Fruity-Nergic
Rue des Caramboles
Mapou
Mauritius

SCOPE:

The HACCP Team have identified the scope of this process as being:

Processing of oranges for final production of heat-sterilized shelf-stable
orange juice. The HACCP team have determined to address the potential
of Microbiological, Chemical and Physical contamination through the
process of intake, handling, processing, storage until despatch to the
distributors facilities.

PURPOSE:
Compliance with FDAs current Good Manufacturing Practice Regulation
21 CFR Part 110 and FDAs Juice HACCP Regulation 21 CFR Part 120.

Product Description
Product Name Orang-i-Nick
Composition Orange juice concentrate, water,
preservatives
Product characeteristics pH of 3.5
Moisture content of 97%
Method of preservation Heat treatment, aseptic packaging
Packaging (inner) Tetra Brik cartons
Packaging (outer) Plastic crates/ pallets
Storage conditions Ambient temperature (20-25C),
refrigerate after opening
Distribution method Ambient temperature (20-25C)
truck/trailer
Shelf life 1 year
Specific labeling requirements Not suitable for people with sulfite
allergies
Not suitable for infants under 1 year
Customer preparation Ready-to-drink
Orang-e-
nick
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HACCP TEAM


Name Position Qualification/Experience
Harry Pillay HACCP team Leader HACCP Trainee Level 1,2,3,
Internal Audit Course, Trained in
GMPs, GHPs and ISO 9001 and ISO
22000, Juice HACCP regulations
Harry Pillay General Manager HACCP Trainee Level 1,2,3,
Internal Audit Course, Trained in
GMPs, GHPs, ISO 9001 and ISO
22000, Juice HACCP regulations
Selvina Kalleeperumal Production Manager HACCP Trainee Level 1,2,3, Trained
in GMPs, GHPs and Juice HACCP
regulations, ad-hoc training in
Process Control and equipment
calibration
Ashvin Khirodhur Quality Assurance Manager HACCP Trainee Level 1,2,3, trained
in Juice HACCP regulations, GMPs,
GHPs,
Enrico Chaitan Maintenance Manager HACCP Trainee Level 1,2,3, trained
in Preventative Maintenance,
HACCP Awareness
Hudaa Neetoo Procurement Manager HACCP Trainee Level 1,2,3,
Internal Audit Course
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Washing
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Bins Bins
Labeling/
Palletizing
Bins
B
i
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s

Administrative Office
FRUITY-NERGIC ENTERPRISE FLOOR PLAN
Changing
room
T
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k

Reception & storage
Washing, sanitizing, rinsing
Grading
Peeling &
Cutting
Pulp & juice
extraction
Filtering
C
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P
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PM
7-9 am
Lot, species, quantity
PM
Throughout shift (TS)
Quality, species

PM/QAM
Time/temperature
Every process
PM/QC
Labels/quantity/
packing
Every pallet
PM/QC
Dispensed volume
Every 30 mins
PM/QC
Product temperature
Every process
W
a
r
e
h
o
u
s
e

PM/QAM
Time/temperature
Every process
PM
TS
[Chlorine], water temperature
PM
TS
[detergent
],
[sanitizer]

PM
TS
GHPs, [detergent], [sanitizer]
TetraPak
cartons
Hydrogen
peroxide
bathing
UV
treatment
Processing
Step
Potential
Hazards
Likely? Severe
?
S/N Preventive measures CCP/C
P
Limit
s
Receiving Pathogenic
vegetative
bacteria &
spore-forming
bacteria (B)

Worms (B/Q)

Pesticides (C)





Stones/sand/s
oil/ metals (P)

Colorants/pig
ments (Q)
L





L

L





L




L
H





L

H





H




L
S





NS

S





S




NS
Control source. Letter of warranty.
Approved suppliers list. No harvest of
drops. Storage at 7C in chiller to
prevent bacterial and fungal
multiplication. Sterilization as final
killing step
Removed at grading stage

Random sampling to test for
pesticide residues. Spray programs
submitted by suppliers, Traceability
between raw material supplier and
end product

Removed at grading stage.
Metal detector after filtration



Removed at washing stage
CP





CP

CCP





CP




QP
-




-

< 10
ppb



-


-
Grading Pathogens
multiplication
(B)

L




H




S




Wash and sanitize hands using hand
dip. Cull out decayed and infected
products.

CP



-
Processing
Step
Potential Hazards
Likel
y?
Severe?
S/N Preventive measures CCP/
CP
Limits
Washing/
sanitizing/
rinsing
Pathogen
multiplication,
infiltration or
survival

Pesticide
infiltration (C)
L




L
H




H
S




S

Using chlorinated wash at
effective concentration,
dosage regularly monitored.
Sterilization as eventual heat
killing step
Temperature of water 7C
higher than core orange
temperature
CP




CP

-




-
Peeling &
Cutting
Pathogen
transference
and
multiplication
(B)

Pesticides
transference (C)


Metal/Blades (P)
L




L



L
H




H



H
S




S



S
High acidity prevents
multiplication. Destruction by
heat-killing step


Washing of knives at every
break


Metal detector after filtering
CP




CP



CP
-








Processing
Step
Potential Hazards
Likel
y?
Severe?
S/N Preventive measures CCP/C
P
Limits
Extraction
and
Filtering
Pathogen
survival and
multiplication
(B)

Spoilage
bacteria/molds
(B/Q)

Metal/Blades
(P)

L




L



L
H




M



H
S




NS



S
Destruction by sterilization -
heat killing step







Metal detector
CP




CP



CCP
-




-



< 2.5
mm
Sterilization Vegetative
pathogens

Pathogenic
sporeformers

Ascospores and
mycotoxin
formation
L


L


L
H


H


H
S


S


NS
Heat treatment at 85C for
30s. pH prevents outgrowth of
bacterial spores
pH prevents outgrowth of
spores and toxin formation

Anti-fungal preservatives

CCP


CP


CP
T:85C
t: 30s
Processing
Step
Potential Hazards
Likel
y?
Severe?
S/N Preventive measures CCP/C
P
Limits
Cooling &
holding
Pathogenic and
Spoilage
thermophilic
sporeformers
(B/Q)


Metal, rust
L






L
H






H
S






S
Product temperature to reach
< 35C. pH prevents
outgrowth of spores. Limited
oxygen availability prevents
outgrowth of aerobic spore-
formers.

Metal detector after packaging
CP/Q
P





CCP
-





-
Processing
Step
Potential Hazards
Likely
?
Severe?
S/N Preventive measures CCP/CP Limits
Forming/
filling/seali
ng
Pathogen
multiplication
(B)

Pathogen
cross-
contamination
(B)

Metals (P)

Underfilling
(Q)
L


L





L

L
H


M





M

H
S


NS





S

S
100% seal inspection
on-line , verification
of sealer bar,
random sampling for
seal strength and
integrity



Metal detector after
packaging
Calibration of
dispenser
CCP








CCP
Seal
strength:
5kg/100mm
Seal width:
10 mm
0 seal
defects




< 2.5 mm
Packaging/l
abeling/pall
etizing
Pests, rodents
(B/Q)


Wrong label
(Q)
L



L
M



L/M
NS



NS
Pallets placed at 18
cm from wall
Cling film wrapping

Package inspection
QP



QP
-



-