IMPLEMENTATION OFHAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)SYSTEM TO THE ALCOHOLIC   BEVERAGE INDUSTRY                ...
INTRODUCTION• Real target- minimization of unacceptable unsafe  products• Prior to initiating HACCP system, company must  ...
HACCP TeamNames of          Titles/responsibilities   Educational     Experience or trainingmembers                       ...
Product DescriptionNAME OF PRODUCT               RED WINEFOOD SAFETY CHARACTERISTICS   pH : 3.3-3.5                       ...
INTENDED USE  Intended use      • Retail, ingredient, institutionalIntended & likely   consumers        • Adults, elderlyD...
RED WINE• Red wine is made from dark-coloured  (black) grape varieties• Actual colour range- intense violet  (young wines)...
Plant layout
PROMINENT HAZARDS IDENTIFIED                  • Fruit with rotten parts   PHYSICAL       • Bottle condition               ...
CCP-1 (Harvesting)• Grape harvesting is CCP comprising both physical & chemical hazards• Physically, grapes should be soun...
CCP-2 (Alcoholic Fermentation)• carried out by strains of Saccharomyces cerevisiae  - grows at low pH values typical for g...
CCP-3 (Must)• Possible contamination of must  with killer yeasts result in stuck  fermentation• Attention should be paid t...
CCP-4 (Maturation)• Maturation step often lasts 6–24 months & takes place in oak barrels• During maturation a range of phy...
CCP-5 (Stabilization)• Reason for stabilization- production of permanently clear &  flavor fault-free wine• Procedure  a) ...
CCP-6 (Bottling)• Wine is bottled in glass bottles sealed with cork which must pass a  decontaminating step & an inspectio...
CCP-7 (Storage)• Shipping & storage of wines at elevated temperatures can  initiate rapid changes in color & flavor of win...
CRITICAL LIMITSPROCESS STEPS   CRITICAL LIMITSHarvesting      Rotten parts reduced to acceptable level                Per ...
MONITORING PROCEDURES FOLLOWED• Harvesting: Inspection during harvesting, Specific  chemical analyses• Fermentation: Speci...
CORRECTIVE ACTIONS APPLIED• Fermentation- Rejection of specific batch,  dilution with large quantities, machinery  modific...
THANK YOU
Implementation of hazard analysis critical control point (
Implementation of hazard analysis critical control point (
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Implementation of hazard analysis critical control point (

  1. 1. IMPLEMENTATION OFHAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)SYSTEM TO THE ALCOHOLIC BEVERAGE INDUSTRY Submitted by: Abhishek Rana Amber Awasthi Ankita Pathania Charul Sharma Deepak Dhar Devansh Jaiswal
  2. 2. INTRODUCTION• Real target- minimization of unacceptable unsafe products• Prior to initiating HACCP system, company must endeavor to put together HACCP plan : a) identify HACCP resources & assemble team b) describe food & its distribution method c) state clearly intended use & consumers d) develop a process flow diagram e) verify validity of this diagram in practice (operation)• 2 most important stages- Fermentation & bottling
  3. 3. HACCP TeamNames of Titles/responsibilities Educational Experience or trainingmembers qualificationAbhishek Rana Clean up/sanitation B. Tech (FST) _Amber Awasthi Outside Expert B. Tech (FST) _Ankita Pathania Laboratory, Quality B. Tech (FST) _ AssuranceCharul Sharma Plant Manager B. Tech (FST) _Deepak Dhar Production B. Tech (FST) _Devansh Jaswal Engineer B. Tech (FST) _
  4. 4. Product DescriptionNAME OF PRODUCT RED WINEFOOD SAFETY CHARACTERISTICS pH : 3.3-3.5 Alcoholic content : 11-15%PACKAGING USED Glass bottles sealed with cork with final packaging of silver & gold paper ; bag in boxesLABELLING REQUIREMENTS Alcohol content, sulphite declaration & health warning statementSTORAGE & DISTRIBUTION Store in dark, moderately humid place at 130CINTENDED CONSUMERS AdultsINTENDED USE Ready to drink, as an ingredientSHELF LIFE Bottled : 2-3 years Opened (refrigerator) : 1-2 weeks
  5. 5. INTENDED USE Intended use • Retail, ingredient, institutionalIntended & likely consumers • Adults, elderlyDistribution area • NationwideConsumer of food • Adults (70%), elderly(20%) Distribution • Preferably refrigerated (130C)
  6. 6. RED WINE• Red wine is made from dark-coloured (black) grape varieties• Actual colour range- intense violet (young wines), brick red (mature wines) & brown (older red wines)• Juice from most black grapes is greenish-white; red colour comes from anthocyanins present in the skin of the grape• Red-wine production process involves extraction of colour & flavour components from grape skin.
  7. 7. Plant layout
  8. 8. PROMINENT HAZARDS IDENTIFIED • Fruit with rotten parts PHYSICAL • Bottle condition • Cork sizing • Pesticide residues • Heavy metals CHEMICAL • Residues of ethylene glycol & detergents • Methanol content • Ethyl carbamate formation • Microbial contamination of culture • Water microbiological qualityMICROBIOLOGICAL • Presence of yeasts & LAB • Cork microflora
  9. 9. CCP-1 (Harvesting)• Grape harvesting is CCP comprising both physical & chemical hazards• Physically, grapes should be sound without rotten parts, otherwise oxidative & microbial contamination can rapidly develop• Harvesting should be conducted with greatest possible care & efficient disease management system should be applied• Pesticides should be handled with care as they constitute chemical hazards.• At time of harvest, the grapes must have also reached correct maturity when Brix & Total Acidity levels indicate maturity of wine• Pesticide & fungicide residues on surface of berries constitute chemical hazards• Rapid & simple gas chromatography- method for determination• Maximum residue limits for pesticides (grapes & wines)- Codex Alimentarius (45)• Bulk bins used for grapes transportation, should be effectively decontaminated to avoid any microbial infection
  10. 10. CCP-2 (Alcoholic Fermentation)• carried out by strains of Saccharomyces cerevisiae - grows at low pH values typical for grape must (pH 3.2–4)• chemical hazards : heavy metals presence (As<0.2, Cd<0.01, Cu<1, Pb<0.3 mg/L), methanol content (300 mg/L ), ethyl carbamate content, pesticide residues (as mentioned in the Codex Alimentarius) & residues of detergents (absence) & ethylene glycol (absence)• desirable temperature varies within the range of 25–28◦C
  11. 11. CCP-3 (Must)• Possible contamination of must with killer yeasts result in stuck fermentation• Attention should be paid to added amount of SO2 i.e.175mg/L in order to inhibit
  12. 12. CCP-4 (Maturation)• Maturation step often lasts 6–24 months & takes place in oak barrels• During maturation a range of physical & chemical interactions occurs among barrel, surrounding atmosphere & maturing wine, leading to transformation of flavor and composition of wine• Oak barrel should be fault-free & undergone decontamination treatment• Wood must be free of pronounced or undesirable odors, which could taint the wine• White wines are matured in oak for shorter periods than red wines & in conditioned barrels to release less extractable (tannins)• Another CCP- inhibition of O2 penetration through wood or during racking & sampling of wine• Extensive penetration can cause various sensory changes (oxidized odor, browning, loss of color in red wines, activation of spoilage bacteria & yeasts, development of ferric casse & precipitation of tannins)
  13. 13. CCP-5 (Stabilization)• Reason for stabilization- production of permanently clear & flavor fault-free wine• Procedure a) tartrate stabilization by chilling wine to near its freezing point & filtering or centrifuging to remove crystals b) protein stabilization with absorption, denaturation or neutralization by fining agents (bentonite) c) polysaccharide removal with pectinases that hydrolyze polymer, disturbing its protective colloidal action & filter plugging properties d) metal casse (Fe, Cu) stabilization• Ferric casse is controlled by addition of agents (bentonites, proteins) controlling flocculation of insoluble ferric complexes• Wines with Cu content greater than 0.5 mg/L are particularly susceptible to Cu casse formation
  14. 14. CCP-6 (Bottling)• Wine is bottled in glass bottles sealed with cork which must pass a decontaminating step & an inspection control to assure absence of any defects & stability of product until its consumption• Cork should be correctly sized, 6–7 mm bigger than inner neck diameter, to avoid any possible leaks• Hazards include : cork microflora, residues of heavy metals, SO2, pesticides & detergents & absence of cracks, scratches & rifts in lute• CL for cork is absence of LAB & yeast, which can be assured with microbiological analysis• For long storage of wine longer & denser corks are preferred• Headspace O2 might affect product quality by causing disease of “bottle”• CL for SO2 – 175mg/L , for As < 0.2 mg/L, Cd < 0.01 mg/L, Cu < 1 mg/L, Pb < 0.3 mg/L
  15. 15. CCP-7 (Storage)• Shipping & storage of wines at elevated temperatures can initiate rapid changes in color & flavor of wine• Direct exposure to sunlight corresponds to effect of warm storage temperatures• Temperature affects reaction rates involved in maturation, such as acceleration of hydrolysis of aromatic esters & loss of terpene fragrances• Temperature can also affect wine volume & eventually loosen cork seal, leading to leakage, oxidation & possibly microbial formation resulting in spoilage of bottled wine
  16. 16. CRITICAL LIMITSPROCESS STEPS CRITICAL LIMITSHarvesting Rotten parts reduced to acceptable level Per pesticideaccording to Codex Alim.Fermentation As < 0.2, Cd <0.01, Cu < 1, Pb < 0.3 (mg/L) Pesticide residues according to Codex Alim Ethylene glycol & detergent residues Absent in 300 mg/LMust 100% cleanMaturation Absence of yeasts, molds and LABStablization As < 0.2, Cd <0.01, Cu < 1, Pb < 0.3 (mg/L)Bottling As < 0.2, Cd <0.01, Cu < 1, Pb< 0.3 (mg/L) Pesticide residues according to Codex Alim Absence of rifts in lute, cracks, scratches Yeast, LAB absenceStorage wine quality as set by each plant
  17. 17. MONITORING PROCEDURES FOLLOWED• Harvesting: Inspection during harvesting, Specific chemical analyses• Fermentation: Specific chemical analyses, Gas chromatography• Must: Microbiological analyses• Maturation: Microbiological analyses• Stabilization: Specific chemical analyses• Bottling: Specific chemical analyses, Visual inspection, Sample measurements, Microbiological analyses• Storage: Organoleptic controls
  18. 18. CORRECTIVE ACTIONS APPLIED• Fermentation- Rejection of specific batch, dilution with large quantities, machinery modification• Bottling- Modification of CIP, Disinfect area, rejection of faulty bottles• Storage- Rejection of faulty batches
  19. 19. THANK YOU
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