Quality Management... (1).pptx

QUALITY CONTROL IN FOOD INDUSTRY
o Content
o Quality of foods, quality factors and principles and methods for
determination of various quality factors under appearance,
kinaesthetic and flavour properties. Effects of various cultural
practices on quality of foods. Quality standards: Quality
control: Modern and total quality control: Subjective and
objective methods for determination of quality of foods.
Factors affecting quality of food products. Food products
development: Sensory evaluation of foods: Various methods,
their description and implications. Application of sensory tests
to food industry problems. Instrumental and microbial
methods of quality control and assurance. Hazard Analysis
and Critical Control Points (HACCP). Food regulation and
compliance. Food adulteration and misbranding. Products
specifications. National and international food standards

QUALITY
1. Something inherent and distinctive
Synonyms: affection, attribute, character, characteristic,
feature, mark, peculiarity, property, savor, trait, virtue
2. A usually high level of merit or superiority
Synonyms: caliber, merit, stature, value, virtue, worth
3. Degree of excellence
Synonyms caliber, class, grade
4. Composite of characteristics that have significance and
make for acceptability
 “The totality of features and characteristics of a product
that bear on its ability to satisfy stated or implied needs”
International Standard ISO 8402-1986:
Quality Vocabulary

DIMENSION OF QUALITY
DESIGN CONFORMANCE
Customers
Manufacturing
Other
Stake Holders
Performance
Features
Reliability
Conformance
Durability
Service-
ability
Aesthetic
Perceive
quality
(Vosconcellos, 2004)

WHAT IS FOOD QUALITY?
 degree of excellence
 a value of products
 fitness for use/ consumption –utilitarian terms
The requirements necessary to satisfy the needs
and expectations of the consumer.
CONSUMER SATISFACTION

FOOD QUALITY
 Food quality is the extent to which all the established
requirements relating to the characteristics of a food are
met.
 Examples:
 Identity of a food in relation to a standard (e.g.,
standardized food)
 Declared gross or net quantity (e.g., weight or
volume) of a unit of the food or net fill of a food
container
 Declared or claimed amount of one or more stated
components of a food

Intrinsic
factors
Food quality
Nutritional
value,
health
aspects
Shelf
life
Safety
(microbial,
chemical)
Packaging
Taste,
flavour,
texture
Shape,
appearance
Quality factors
(van Boekel, 2006)

Extrinsic
factors
Intrinsic
factors
Availability
Regulations
Emotions
(tradition,
culture)
Food quality
Nutritional
value,
health
aspects
Shelf
life
Safety
(microbial,
chemical)
Convenience
Price,
brand
name
(After)
sales
service
Packaging
Taste,
flavour,
texture
Shape,
appearance
(van Boekel, 2006)
Broadening of the quality concept

QUALITY FACTORS DETECTABLE BY SENSE
 Quality detectable by sense are characterized by the
following factors
 Appearance factors: eye appeal judged by sense of sight
 Dimensional: size, shape, wholeness, pattern
 Defects: damage, bruising, extraneous matter, specks, sediment,
 Spectral: Gloss, transparency, turbidity, color
 Consistency: viscosity, gel, flow, spread
 Kinesthetic Factors: hand and mouth feel, judged by sense of
touch
 Hand feel: firmness, softness, juiciness
 Mouth feel: chewiness, fibrousness, grittiness, mealiness,
stickiness
 Flavour factors: judged by sense of taste and smell
 Odor: fragrant, acid, burnt, goaty etc.
 Taste: sweet, sour, salty, bitter, etc
 Off-flavour: enzymatic, physiological, chemical, contaminated,
over-cooked, stale, etc.

PRINCIPLES AND METHODS OF
DETERMINATION OF QUALITY FACTORS
 These quality characteristics may be measured by
 Objectively
 Physical
 Chemical procedures
 Subjectively
 Sensory evaluation
 Two principles involved in any measurement
 Precision
 Ability to duplicate results.
 Statistical parameter like Coefficient of Variability is used to
measure it
 Accuracy
 Refers to the degree to which instruments or procedures reflect
human evaluations
 Statistical parameter like Coefficient of Correlation is used to
measure it
 Increased precision tends toward greater accuracy

APPEARANCE FACTORS
 Size and distribution factors includes in this category
 Size, shape, wholeness (degree of whole or broken) and
pattern (way of lying out) are common appearance
factor.
 For packaged foods, the containers and labels are
important towards appearance of foods
 For fresh produces, size, shape, wholeness, defects and
color are important
 Ordinarily, simple devices are used, like
 Scales
 Screens
 Micrometers
 Planimeters
 Sedimentation test or displacement in liquid media

DEFECTS
 Imperfections due to the presence of something
that detracts from perfection
 In statistics, tolerance limit (TL) is used
 TL is allowable maximum number of defective
 Quantitative measurement is very difficult; e.g. a
spot dark enough or large enough to call it defect
 Setting TL in such case is difficult and lengthy
procedure
 Defects in plant products
 Genetic-physiological: hereditary abnormalities
 Entomological-pathological: insect or disease injury
 Mechanical: handling and manufacture
 Extraneous Foreign matter: harmless materials

DEFECTS
 Instruments available for measuring the defects
factors are merely aids to visual examination
 Such aids may serve the following purposes:
 Improve visibility: passing before magnified light source
 Standardize condition: Uniform condition
 Reference standards: model photo, drawing, color chips
 Counts and measures: no and size of defects; electronic
defect counter
 Isolation of defects: flotation, elution, or electronic
sorting

APPEARANCE FACTORS
 Color: Spectral distribution of light
 Common attributes are glossiness, transparency,
haziness and turbidity
 Commonly an index of ripeness or spoilage
 Common examples
 potatoes darken in color indicates over fried
 Dark tomato powder indicates high moisture level
 Surface color of chocolate tells its storage history
 Colorimeters or spectrophotometers are used to determine
color of transparent liquid
 Color of liquid or solid is determined by comparing it to
defined color tiles or disk
 Color measurement is quantified by three parameters: value,
hue and chroma
 Value refers to the lightness or darkness
 Hue determines whether the color is red, green,, or yellow
 Chroma refers to the intensity of light

VISCOSITY AND CONSISTENCY
 Importance attributes for semi-solid and
concentrated foods
 These parameters used as QCT on raw products or
products at various stages in the process
 Duration and amount of heat applied
 Disaggregation criteria; protein, starch, pectin
 Polysaccharides properties
 Viscosity: flow of liquids divided in layers
 Consistency/Apparent viscosity: the resistance to
flow between the liquid layers
 Constant consistency is called viscosity/Absolute
viscosity

VISCOSITY AND CONSISTENCY
 Types of viscosimeters and Consistometers:
 Flow through a capillary tube: pure fluids, The Ostwald
Viscometer, flow in a capillary tube
 Efflux through an orifice: suitable for highly mobile materials
 Falling-weight
 Resistance to rotation of a spindle
 Brookfield Syncro-lectric viscometer
 Stormer Viscosimeter
 Test material rotating around a spindle
 MacMichael viscometer
 Fisher Electroviscometer
 Poland rotating cylinder viscometer
 Power consumption
 Penetration
 Spread or flow
 Bostwick Consistometer
 Adams Consistometer
 Plastometer
 An ultrasonic viscometer

KINESTHETIC FACTORS
 KF deals with the factors revealed when comes in contact of
 Hands
 Lips
 Tongue; and also
 During chewing
 The common characteristics are toughness, viscosity, grittiness
 Principle is the sensations experienced by the consumers of the food
 Physical instruments or chemical procedures are used
 First instruments by Prof. O. M. Morris in 1917
 Ripeness of apple
 Pressing using ball
 Ibs of pressure required to press a marble, 5/8 in in diameter
 Other pressing devices: rods, bars, blades, wires or needles
 Weight, columns of liquid or electric motors provide power source
 There are many instruments developed, however basic principles are the same:
 Compression: squeezing to minimum vol. without crack
 Shearing: force required to spilt into two or more sliding beyond one another
 Cutting: force required to divide remaining in their original position
 Tensile strength: force required to pull material apart; toughness of materials
 Shear-pressure: first compress and then shear the food; tenderometer, texturemeter
 See Table-11

PRINCIPLES OF TEXTURE MEASUREMENT
=
=
=
=
Compression Shearing
Force
Force
Force Force
Force
Force
Force Force Force Force`
Cutting Tensile Strength

FLAVOR FACTORS
 Factors evaluated by the senses of taste and smell
 Difficult to evaluate objectively; physiological sensation
is by definition subjective
 Degree of sweetness; sugar determination or TSS
 Saltiness; by chloride or sodium
 Sourness; by total acid or pH
 Off-flavour; by volatile acids, amines and succinic acid
 Rapid and practical method is still absent
 Subjective evaluation is still the best
 The bulk of quality evaluation is still done by sensory
methods
 Trained inspectors carry out this
 Subjective evaluation is very critical and depends on many
factors
 Seasons
 Absence of reference

SENSORY EVALUATION
 SE is used to evaluate quality related to sense
 Subjectively; particularly flavour
 Early time, it was done by trained expert
 Later on, replaced by panel consisting panelist
 Panelist are highly sensitive and consistent
 Obtained by training & repeated tests
 Panelists test food through planned experiments
 Judgments are quantified by appropriate statistical test
 Significance of variation of average scores
 Contribution of individual quality characteristics to overall quality
 Panel consists of small number of people
 Look after quality control of
 In-line
 final product
 Process development
 Preliminary acceptance testing
 Consumer survey; untrained person having large number of persons
 Sensory test should be done before the samples are prepared and packed.

LABORATORY SET-UP AND EQUIPMENT
 Set-up may be simple or elaborate
 General decoration is better
 A typical layout should consist of
 The reception and briefing room providing people control
 The preparation room for preparing and serving
 with extra large storage space
 plenty of serving utensils
 The panel booth area located in between or adjacent to the other two rooms
 Whole area or at least the panel booth area, is perfectly air conditioned.
 The booth should be
 Identical
 Uniformly illuminated
 Provided with drinking water, glass, towel and a basin
 Convenient utensils are
 Ruby-red glass (3 oz size)
 Custard type china dishes (6 oz size)
 Cups (3 oz size)
 Glass shifters (8-12 oz sizes)
 Small stainless steel forks and spoons
 Watch glasses as covers
 Glass-stoppered bottles for odor test
 Electric rather than gas equipment is preferred for cooking.

PANEL SELECTION AND TRAINING
 The requirement for panel membership are:
 Good health
 Average sensitivity
 High degree of personal integrity
 Intellectual curiosity and interest in sensory evaluation work
 Ability to concentrate and learn
 Availability and willingness to spend time in evaluation and
reporting
 Types of panels
 Laboratory panel: for specific product or purposes
 Flavour and texture profile panels: research and product
development; 5-10 in number
 Semi-trained panels: technical people and their families
 Consumer panels: untrained people

JUDGING QUALITY
 Judging should be done in individual booths
 Independent judgment; no consultation except with panel
leader
 Testing should be an hour after any normal meal
 The best time: 10 am to 12 noon or 3 to 5 pm
 Panel member should not smoke or chew pan or supari for at
least half an hour prior to the test
 Quickly but not hurriedly first
 Prolong testing should be avoided
 Testers may either swallow or spit out the samples after
testing
 The questionnaire or score card should be prepared carefully
for each test
 Card should be clearly typed or printed
 Card should be simple and free from ambiguous terms

TEST METHODS
 A. Difference: Qualitative
 Paired comparison
 Both trained or untrained panelist
 If trained, no of panelist 5-12
 If untrained, no of panelists 72-80
 No of sample 2
 Statistical analysis of data: Binomial distribution
 Duo-Trio
 Trained
 No of panelists 5-12
 Sample 3 (2 identical and 1 different)
 Triangle (Triad)
 Trained
 Sample 3 (2 identical and 1 different)

TEST METHODS
 B. Rating (Quantitative difference)
 Ranking
 Both trained or semi-trained or untrained panelist
 If semi-trained, no of panelist 10-25
 If untrained, no of panelists 72-80
 No of sample 2-7
 Statistical analysis of data: Rank analysis table
 Single sample
 Both trained or untrained
 If untrained, no of panelist 72-80
 No of sample 1
 Statistical analysis of data: analysis of variance
 Two sample difference
 Trained
 No of panelist 6-25
 No of sample: 4 pairs of unknown and control
 Multiple sample and quality difference
 Both trained or semi-trained
 If semi-trained, no of panelist 10-25
 No of sample 3-6 including control and depending on no of quality factors
 Statistical analysis of data: analysis of variance and multiple Range Test

TEST METHODS
 Hedonic
 Semi-trained
 No of panelist 10-25
 Numerical scoring
 Both trained or untrained
 If untrained, no of panelist 72-80
 No of sample for trained 1-6 up to 5-10
 No of sample for untrained 1-4
 Composite
 Trained

TEST METHODS
 C. Sensitivity
 Threshold
 Untrained
 Panelist: no limit
 Dilution
 Trained
 Panelist: 12-24
 Descriptive flavour profile
 Trained
 Panelist: 3-6

DIFFERENCE TEST
 Comparison of two similar products
 To find whether or not, two materials are different in
some respect
 Paired Comparison Test:
 Used for difference, intensity, or preference test
 Here two sample
 One standard/control
 Other experimental one
 Panelists are asked
 If the samples are different and/or
 Intensity of specified sensory characteristics
 A positive answer is required
 The probability of placing the sample in a certain order is 0.5
 In case of replication, each treatment is compared

SYSTEM EVALUATION CARD
System Evaluation Card
Paired comparison test
Name: ……………………………………… Date: ………………..
Product:
You are given one or several pairs of samples.
Evaluate the two samples in the pair for ………..
Code No. of pairs Yes No
---------- ------ ---------
---------- ------ ----------
---------- ------ ----------
---------- ------ ----------
Is there any difference between the two samples in the pair?
Signature

PAIRED COMPARISON TEST
 Two types
 Paired difference test
 To determine if the difference between samples can be
discriminated
 If finds difference, ask to describe difference
 Paired Intensity test
 Two distinct samples are presented and asked which sample
has greater or lesser intensity of particular factors
 Like sweetness, toughness, flavour, etc
 Pretest is done to select concentration

PAIRED COMPARISON TEST
A randomized design for presentation of sample for paired CDT
Pair number
Judge number
1 2 3 4
1 AB AA BB BA
2 BA AB AA BB
3 BB BA AB AA
4 AA BB BA AB
A randomized design for presentation of sample for paired CIT
Pair number
Judge number
1 2 3 4
1 AB BA BA AB
2 BA AB BA AB
3 BA BA AB AB
4 AB AB AB BA
035 759
B A

EXAMPLE
 Tomato juice samples with added salt were tasted in
paired comparison with the same juice sample without
added salt by an experienced judge 12 times. The judge
was asked to identify the saltier of the two samples and
did so for 10 comparisons. Does this mean that the
judge could distinguish the salted from the unsalted
juice?
 Solve by binomial expansion
 Solve by using table: Table gives the sums of various
numbers terms for a given (p+q)n for a given number of
events (n)/sample size.
 In Table, n= denotes No. of events/given sample size
 x= number of cases

ONE-AND TWO-TAILED TESTS
 A sample of 10 was drawn and it is found that there
7 men ad 3 women. Does this mean that there are
more men than women in the university?
 H0: there were equal no. of men and women, H1:
there were more men than women
 p= probability of getting men; q= probability of
getting women on H0 =1/2
 (p+q)10
 If possible alternate hypothesis is unknown, use
two-tailed test.

DU0-TRIO
 What is the main disadvantage of preference test?
 In D-T, which of two samples are the same as a
standard same presented before the test.
 Statistical approach for paired comparison and
Duo-trio are the same
 H0: the judge cannot distinguish between the two
samples
 One-or two-tailed test?

TRIANGLE TEST
 The judge has to pick out the odd sample from a
group of three
 Two the same, one different
 Statistical analysis: one tailed binomial
 why?
 Where is the main difference?

SENSORY TEST AND THEIR ANALYSIS
Difference tests
Paired-comparison: A vs. B
Which is greater in a given attribute A or B One-tailed binomial test, p=q=1/2; use one-tailed or two
tailed table
Is there a difference between the two? Same or
difference
Two-tailed binomial test, p=q=1/2; use two tailed table
Duo-trio: A: A vs. B
Which is the same as the standard? A or B One-tailed binomial test, p=q=1/2; use one-tailed table
Triangle: A
B B
Which is the odd sample? A or B? One-tailed binomial test, p=1/3, q=2/3; use one-tailed
table
Preference test
Paired-comparison: A vs. B
Which do you prefer? A or B? Two-tailed binomial test, p=q=1/2, use two-tailed table

EXAMPLE
 Ex-1:A judge was able to tell a reformulated high-fiber
exploding candy product from the original product on six
out of seven triangle tests. Does this indicate that the
judge could tell the difference between the two
products?
 Ex-2: In a paired-comparison preference test, a judge,
who could distinguish between two instantly
effervescing, chewable multivitamin capsule products A
and B, indicated that he preferred product A to product B
six out of 10 times. Does this indicate a significant
preference?
 Ex-3: Thirty seven out of 50 experimental subjects
improved their wine testing ability while 13 got worse
when a new psychophysical technique was adopted.
Does this indicate that wine-tasting ability tended to
improve by more than mere chance when the new
psychophysical technique was adopted?

CHI-SQUARE TEST
 Uses to test hypotheses about frequency of
occurrence
 Binomial test
 a test of frequency of occurrence in two categories
 More than two categories:
 ‘like’ vs. ‘indifferent’ vs. ‘dislike’ or ‘too sweet’ vs.
‘correct sweetness’ vs ‘not sweet enough’
 Chi-square distribution
 A chi-square value is calculated and compared

CHI-SQUARE TEST
 A sample of 10 was drawn and it is found that there
7 men ad 3 women. Does this mean that there are
more men than women in the university?
 Solution:
 One-or two tailed test
 Like before
 Degree of freedom
 the no. of categories to which data can be assigned
freely (df)

CHI-SQUARE TEST FOR MORE CATEGORIES
 Example: A sample of 44 birds from which four bird
species, A, B, C, and D were drawn. Species A and
B were 16 each and 6 each of C and D. Does it
indicate that there are equal number of species in
the ecological niche

CHI-SQUARE: TWO WAY CLASSIFICATION
 Categorize sample in two dimensions
 Example: How the interest of men and women vary
in their appreciation of a new synthetic leather
textile product. Seventy nine men sampled of which
58 approved, 11 were neutral, and 10 disapproved,
while of the 83 women sampled, 35 approved, 25
neutral, and 23 disapproved.
 Solution:
 1st dimension alone men vs. women
 2nd dimension along approve
 Expected fr,
E=
nc X nr
N

WORK OUT EXAMPLE
 Ex-1: Sixty randomly selected customers in a store
were asked to select which product they preferred
from three shampoos with added beer, eggs,
protein, herbs, and yogurt. If 30 preferred product
A, 18 B, and 12 C, would this represent significant
differentiation in preference?
 Ex-2: In a consumer study investigating
preferences for “organic” versus regular prune
juice, 50 males and 50 females were chosen at a
supermarket and asked which of the two they
preferred. Ten males and 20 females preferred the
organic prune juice. Was there a significant
difference in the preferences between males and
females?

EXERCISE 1
 In the pretest, unflavoured orange squash is prepared and divided into two portions. To one portion, a detectable
quantity of orange oil from source A is added and to the second portion, no oil is added and used as control (C).
The two squashes are diluted (1+3) with water. To each judge, 2 randomly arranged pairs are presented, and
they are asked to pick the sample having the stronger flavour. The results of analysis by 15 judges are:
Judge Sample chosen as having
strong flavour
Correctness of
judgment
I pair II pair
1 A A ++2
2 A C +-1
3 C A -+1
4 A A ++2
5 A A ++2
6 A A ++2
7 A A ++2
8 A A ++2
9 A A ++2
10 C C --0
11 A A ++2
12 A A ++2
13 C A -+1
14 A A ++2
15 A A ++2
HW: In a consumer study investigating preferences
for “organic” versus regular prune juice, 50 males
and 50 females were chosen at a supermarket and
Asked which of the two they preferred. Ten males
and 20 females preferred the organic prune juice.
Was there a significant difference in the preferences
between males and females?

STUDENT’S t TEST
 Parametric test
 Difference betn the means of two samples data
 Samples must be drawn from populations with normal
distribution
 It tests whether difference between means of samples is
an indication of their source population
 The value of t is calculated and compared.
 One sample t test:
 Example:
 The average rate of packing of pumpkins by regular workers
was 16 per minute. However, a group of 10 packers who had
newly joined the packing plant claimed to be significantly
faster than average. They had a mean rate of 17 per minute
with a standard deviation, S=3.13. Were they significantly
faster then average?

TWO SAMPLE t TEST
 One sample test
 Whether sample drawn from population
 Two-sample t test
 Whether two samples drawn from
 Same populations; or
 Different populations
 Related sample design
 Same judges in different conditions
 Independent sample design
 Different judges in each condition
 Related sample design
 Example: It was believe that viewing certain meats under red light might
enhance judges’ preference for meat. The same cuts of meat were
viewed by judges under red and white light. They were rated on a
complex preference scale.
 Under white light: 20, 18, 19, 22, 17, 20, 19, 16, 21, 19
 Under red light: 22, 19, 17, 18, 21, 23, 19, 20, 22, 20
 Does the preference scores under light are different from those under
white light?

TWO SAMPLE T TEST
 Independent sample
 Two sets of data
 Data coming from two different sets of subjects under
different conditions
 Example
 Trained and untrained judges were given a series of
tests and the average scores over the tests are given
below for each subject. Note that for an unrelated
samples test, the samples need not be exactly the same
size.
 Untrained subjects: 3, 5, 6, 4, 3, 3, 4
 Trained subjects: 5, 8, 9, 6, 12, 9, 7, 6

ANOVA
 t-test
 differences betn the means of two samples
 Related samples or independent-sample design
 What happened in case of more than two samples?
 An alternate procedure is used. It is called Analysis of
Variance (AOVA)
 It compares the means from several samples
 And tests whether one or more of them are significantly
different
 ANOVA has also two experimental design
 Related sample design
 Data from several different samples all come from same
subject
 Independent sample design
 Data in each sample come from different subjects

LOGIC BEHIND ANOVA
 Let see an example
 Range of treatment means or
 betn-treatment differences
 Range of score or
 Within-treatments differences/ experimental error
 If BTD>WTD
 The means are significantly different; the treatments have
effect
 If BTD ~ < WTD
 The means are not significantly different; the treatments have
no effect
 This is the basic logic of analysis of variance

F RATIO
 Range is not really the best measure
 There are extreme values
 A middle-range value, the variance, is used instead
 The modified arguments are:
 If BTV>WTV
 The means are significantly different; the treatments have
effect
 If BTV ~ < WTV
 The means are not significantly different; the treatments have
no effect
 We need to calculate and compare.
 The best comparison is to examine ratio

F-RATIO
 Variance calculation is not so straightforward
 Which treatment to calculate WTV
 We have to use total variance to calculate ratio.
 This ratio is called F ratio
 F ratio=total variance (only betn)/Total variance (only
within or error)
 How to compute F?
 Example:
 Imagine three treatments A, B, and C. There are four
separate subjects in each treatment (n=4; N=12). Compute F
value to see whether the means of the three samples are
significantly different. The data for treatment A are 10, 8, 9, 9;
for B 8, 7, 9, 8 and for C 5, 7, 6 and 5.

MULTIPLE COMPARISONS
 ANOVA tells only
 whether differences between means exist or not
 where these differences are???
 It needs to do some multiple-comparison tests
 Only valid after satisfying ANOVA test
 For only two means, no need to perform MCT
 Some of the most common MCTs are:
 Fisher’s LSD test
 Sheffe´ test
 Dunnett test
 Newman-Keuls test
 Duncan’s multiple range test
 Tukey HSD test
 Dunn test

PRINCIPLES OF MCT
 Any of the above methods used to test
 All the procedures involve to calculate a range
 If this range> the difference between the means; the
means are not significantly different
 If this range< the difference between the means; the
means are significantly different
 Consider a set of means: X1, X2, X3, X4, X5

HAZARD ANALYSIS AND CRITICAL CONTROL
POINT (HACCP)
 The principles of HACCP technique were applied
 Chemical processing industry
 Great Britain
 More than 40 years ago
 Pillsbury company together with NASA and US Army’s
research, development and engineering first developed
this system
 First applied to ensure the safety of Astronauts’ food
 WHO recognizes it for prevention of food borne
diseases for over 20 years
 FAO/WHO Codex Alimentarius Commission adopted
HACCP for international trade in 1993

BENEFITS OF HACCP
 HACCP
 ensures safety of food products through preventive measures
 is capable of identifying all potential hazards
 makes easy to introduce technological advances
 directs resources to the most critical part of the food-
processing system
 encourages confidence in food products by improving the
relationship among regulatory bodies, food processors, and
consumer
 promotes continuous improvement of the system through
regular audits
 focuses on safety issues in the whole chain from raw
materials to consumption
 complements the quality management system (e.g., ISO
9000)

DEVELOPMENT OF PLANT SPECIFIC HACCP
PLAN
 Steps in HACCP Plan
 Total 12 steps
 Five preliminary steps
 Seven principles
 Preliminary steps:
1. Assemble the HACCP team
2. Describe the food and its method of distribution
3. Identify the intended use and consumers of the food
4. Develop a flow diagram which describes the process
5. Verify the flow diagram

PRINCIPLES OF HACCP
 Principle No. 1
 Conduct a Hazard Analysis:
 Prepare a list of steps in the process where significant hazards occur, and describe
the preventive measures.
 Principle No. 2
 Identify the Critical Control Points (CCP’s) in the process.
 Principle No. 3
 Establish critical limits for preventive measures associated with each identified
CCP.
 Principle No. 4
 Establish CCP monitoring requirements. Establish procedures for using the
results of monitoring to adjust the process and maintain control.
 Principle No. 5
 Establish corrective action to be taken when monitoring indicates that there is
a deviation from an established critical limit.
 Principle No. 6
 Establish effective record keeping procedures that document the HACCP
system.
 Principle No. 7
 Establish procedures to verify that the HACCP system is working correctly.

PLANT-SPECIFIC HACCP PROGRAM
Select Team
Product
Flow
Diagram
Analyze
Hazard
Identify
CCPs
Limit, action
Monitor
Identify the team responsible for implementing the HACCP program
Describe the product and intended use
Show entry of raw materials, processing steps, packaging, storage,
distribution, and end use
Risk analysis
Establish the critical limits at each CCP, e.g., temperature/time
Sampling plans, test methods, decision criteria, responsibilities of
personnel, documentation , and corrective action
Review current procedures, CCPs and monitoring systems

HACCP TEAM
 Team member
 Production Manager
 Technical expert
 Engineers
 Others (as required)
 Secretary
 Convenes & chairs meeting
 Ensures HACCP principles
 Constructs flow charts
 Advices on PI and PC
 Advises on technical issues
 Identifies hazards
 Supplies information (E&M)
 Recommends new (E,M&P)
 Provides information on specialist area
 Records proceedings of meetings

DESCRIPTION OF THE PRODUCT
 First step of model development
 Helps to describe product
•Product Name
•Composition
•End Product Characteristics
•Method of Preservation
•Packaging – Primary
•Packaging – Shipping
•Storage Conditions
•Distribution Method
•Shelf Life
•Special Labeling
•Customer Preparation

HAZARDS
 Hazards are
 Physical
 Chemical
 Allergenic, and
 Biological

PHYSICAL HAZARDS
 ‘Foreign objects’
 may cause injury if they are hard or sharp
 May cause choking
 Generally impacts fewer people than chemical or microbiological
hazards
 Examples:
 Glass from glass containers, from lamps, glasses; detectable by X-
ray
 Metal from equipment, raw material (soil); detectable by metal
detector
 Stones from raw material (soil); remove by flotation
 Wood splinters from packaging crates or pallets (prefer plastic),
working surface
 Plastic from packaging or protective clothing
 pests (e.g. insects, mice) from raw materials or production
environment
importance of pest prevention programmes
 Foreign bodies can potentially carry a microbiological hazard

CHEMICAL HAZARDS
 Chemical Hazards
 Cleaning/disinfection chemicals
 Pesticides
 Toxic (heavy) metals
 Nitrite and related compounds
 PCB’s / dioxins
 Compounds migrating from packaging materials
 Veterinary residues
 Additives
 Allergens
 Distinction between allergy (e.g. peanut protein) and intolerance (e.g. lactose in milk)
 Allergy can be fatal, sometimes at very low dose of allergen
 Only minority of consumers are sensitive
 Examples: egg, peanut and other nuts, milk, gluten, sulfite

BIOLOGICAL HAZARDS
 Associated with mo that cause food borne
 Infections
 disease caused by ingestion of live microorganisms which colonize
and cause damage to a particular site of the body or to the entire
body
 Intoxication
 disease caused by ingestion of a toxin (= poisonous substance
produced by a microorganism). The producing mo need not be
present or alive at the moment of consumption
Causative mo Infectious? Toxin-producing?
Bacteria + +
Viruses + -
Protozoa + -
Worms + -
Fungi - (exceptional) +
Algae and cyanobacteria - +
Prions + -

SOURCES OF HAZARDS
 Potential hazards and their origins are useful in
monitoring and controlling hazards
 Hazards may originate from
 Raw materials: primary source of contamination
 Meat, poultry, fish and dairy products very sensitive to MH
 Process products to chemical hazards
 Fresh fruits and vegetables to pesticides
 Processing steps
 Machinery
 Handling of foods or ingredients
 Environment conditions

SOME MEASURES TO CONTROL HAZARDS
 1. Measure at the processing and packaging stage
 Raw materials
 Processing steps
 Plant and Machinery
 Storage and Distribution
 Premises
 Personnel
 Measures of Post-processing and packaging stages
 Retail
 Food Service
 The Consumer

HACCP PRINCIPLES
 Principle 2
 Identify the Critical Control Points (CCPs) in the process.
 The “Stop Sign” of the process.
Critical Control Point
A point or step at which control can be applied and is
essential to prevent or eliminate a food safety hazard or
reduce it to an acceptable level.

CRITICAL CONTROL POINTS
 Control Point (CP)
 an activity or operation that affects food safety
 Control Action (CA)
 a control action is any activity or operation that can
eliminate or reduce an existing hazard, or prevent
subsequent hazard development
 CCP
 A CP that is critical to food safety is a CCP
 Two types; CCP1 (C1) and CCP2 (C2)
 CCP1:CCPs at which control is assured,
 CCP2: CCPs at which hazards can only be minimized
and control can not be completely assured

THE DESIGN OF HACCP PLAN FOR CHICKEN
BALL PLANT IN BANGLADESH
 Prerequisite Program (PRP)
 Location
 Premises and Room
 Equipment
 Water supply
 Maintenance and Cleaning
 Pest control
 Waste management
 Sanitation system
 Storage and transportation
 Traceability
 Training

PRODUCT DESCRIPTION
1. Product Name? Chicken Ball
2.
Product
Description?
A small (12-13 g) ball shaped product
prepared from chicken meat, salt,
sugar, spice, flour etc.
3.
How it is to be
used?
Ready to eat but 1-2 min fry in oil or
2 min boil in hot water or 30 second
in oven is recommended.
4. Packaging? Poly bag, Vacuum sealed
5. Shelf life? 2 weeks
6.
Where it will be
sold?
Retail store
7.
Labeling
Instruction?
Keep chilled (0-4 0C)
8.
Distribution
condition?
Chilled (0-40C)

Salt, Spices, Flour,
Meat, flake ice
Deboning
Boiling
Meat Grinding
Chopping
Forming
Cooling & packing
7
Storage &
Distribution
PROCESS FLOW DIAGRAM

HAZARD ANALYSIS
Ingredients and
Materials
Hazard
s
Preventive Measure
Chicken Meat and
skin
B C P
Store at chilled temperature
0-4 0C
Sanitize equipment
Proper personal hygiene
and handling
Salt B P
Quality product supply,
Store at room temperature
Maintain FIFO
Sodium Tri poly
phosphate (STPP)
C P
Quality product supply
Store below 20 0C
and handling
Spice powder B C P
Store below 20 0C
and handling
Wheat Flour as
binder
B C P
Store below 20 0C
and handling
Maintain FIFO
Ice B C P
Assure/Use quality water
for ice making
and handling
Vegetables(Onion,
garlic)
B C P
Physical inspection/cheking
Packaging Materials B C P Quality product supply
Process Step Hazards Preventative Measure
Raw Material
Meat Storage
B C P
Proper equipment setting
Sanitize all the transfer equipment
0-4 0C
Deboning
B C P
Proper Personal Hygiene and handling
Clean and Sanitize associated
equipment
< 12 0C
Grinding
B C P
Clean and sanitize associated
equipment
< 12 0C
Chopping
B C P
Clean and sanitize associated
equipment
< 12 0C, 9 min
Forming
B P
Personal Hygiene
Clean and sanitize forming machine and
associated equipment
Boiling B
78 0C, 10 min
CT> 70 0C
Cooling B
Air Cooling system
Using clean and sanitized equipment
Packing
B C P
Proper vacuum packer setting
Sanitize the container, scale and tools
Proper personal hygiene and handling
Storage &
Distribution
B
0-4 0C
Proper storage and distribution
condition setting
Biological (B), Physical
(P) or Chemical (C)

CRITICAL CONTROL POINT DETERMINATION
Instruction:
Q1: Is there a hazard associated with the raw materials? If No (N), not a CCP, if Yes (Y), proceed to Q2.
Q2: Are you going to process this hazard? If No, CCP, if Yes, proceed for Q3.
Q3: Is there a cross-contamination risk to the facility or to other products which will not be controlled? If No, not a CCP, if Yes, CCP.
Raw material Hazard Q1 Q2 Q3 CCP? Notes
Chicken Meat & Skin
B Pathogen Y Y N No Steam cooking will deal with the microbial hazard of meat
C Antibiotics Y Y N No Proper washing, water quality
P Foreign Materials N -- -- No Personal Hygiene and Physical Inspection
Salt
B Microorganism Y Y N No Personal Hygiene and Cooking of final product
P Insect fragment, hair etc Y Y N No Personal hygiene, sieving and physical inspection, pest control
STPP (Sodium
tripolyphosphate)
C Adulterant Y N -- Yes Quality Product supply is critical
P Foreign materials Y Y N No Personal hygiene and physical inspection
Spices Powder
B Pathogen Y Y N No Personal Hygiene, food storage and final cooking process
C adulterants Y N -- Yes Quality Product supply is critical
P Foreign materials Y N -- Yes Quality Product supply is critical
Wheat Flour
B Organism Y Y N No Personal Hygiene, food storage and final cooking process
C adulterants Y N -- Yes Quality Product supply is critical
P Foreign materials Y Y N No Personal Hygiene and Physical Inspection, pest control
Flake Ice
B Pathogen Y Y N No Personal hygiene and heat processing of final product
C Toxic chemicals Y Y N No Prerequisite program: Quality water supply
P Foreign materials Y Y N No Filter water
Packaging Material
B C P
Pathogen,
Toxic ingredient, foreign
materials
Y N -- Yes Quality Product supply is critical

CRITICAL CONTROL POINT DETERMINATION
Instruction:
Q1: Does this step involve a hazard of sufficient risk and severity to warrant its control? If Yes (Y), proceed for Q2, if No (N), not a CCP.
Q2: Does a preventive measure for the hazard exist at this step? If Yes, Proceed for Q3, if No, proceed for Q2a.
Q2a: Is control at this step necessary for Safety? If Yes, modify the step, process or product, if No, not a CCP.
Q3: Is control at this step necessary to prevent or eliminate or reduce the risk of the hazard to safety level to consumers? If Yes, CCP, if No, not a CCP.
Process Step Hazard Q1 Q2 Q2a Q3 CCP? Notes
RM Storage
B Pathogen Y Y Y Yes Correct storage Time & temperature is critical
C Antibiotics N No PRP: Sanitation system, water quality
P Foreign particles Y Y N No PRP: Personal Hygiene, pest control
Deboning
B Pathogen Y Y N No Proper Temperature inhibit the bacterial growth
C Sanitizer and Cleaner N No PRP: Sanitation system, maintenance & cleaning
P Foreign Materials Y Y N No PRP: Personal Hygiene, pest control
Grinding
B Pathogen Y Y N No Proper Temperature inhibit the bacterial growth
C Sanitizer and Cleaner N No PRP: Sanitation system, maintenance and cleaning
P Foreign materials Y Y N No PRP: Personal Hygiene, pest control
Chopping
B Pathogen Y Y N No Proper Temperature inhibit the growth
C Sanitizer & Cleaner N No PRP: Sanitation system, maintenance and cleaning
P Foreign Materials Y Y N No PRP: Personal Hygiene
Forming
B Pathogen Y Y N No PRP: Sanitation system
P Foreign Materials Y Y N No PRP: Personal Hygiene, pest control
Boiling
B Pathogen Y Y Y Yes
Correct boiling temperature and time is critical,
PRP: water quality
Packing
B Pathogen N No Proper personal hygiene and handling
P Foreign Particles Y Y Y Yes Presence of foreign materials is critical
Storage &
Distribution
B Pathogen Y Y Y Yes Storage & distribution temperature and time is critical

HACCP CONTROL CHART
Process
Step
No of CCP
Hazards Critical
Limits
Monitoring
Procedure
Monitoring
Frequency
Preventive
measure
Corrective
action
Record Responsible
person
Raw &
Packaging
Material
CCP#1
Microbiological
Chemical &
Physical
Contamination
No
unqualified
product be
used
Apply supply
quality
assurance
Each supply
Qualified raw
material supply,
check MSDS,
Approved
Supplier List,
Specification
Change supplier
or brand
Employee
training
Materials
Receiving
report
Quality
Assurance
Manager
(QAM)
RM Storage
CCP#2
Microbial
growth
<4 0C
Max. 3
days
Temperature log
is properly
running and
monitored
Routinely
(morning &
evening)
Proper storage
temperature
and time
Reject the raw
meat
Temperature
log sheet,
Discard
register
QAM
Water
Boiling
CCP#3
Survival of
Pathogens CT≥71 0C
Check the CT,
follow up the
time and
temperature and
record keeping
Each Batch
Check The
Core
Temperature
(CT) of product
Adjust the
temperature and
time by setting
the equipment
well
Call the
engineer to
repair
Time and CT
log,
Maintenance
register
QAM
Packing
CCP#4
Physical
contamination
No foreign
material,
No leakage
Visual
Inspection by
Packing
operator
Each Pack
Personal
hygiene and
physical
inspection
Retain, rework
or discard
based foreign
material
identified
Inspection
Report
QAM
Storage &
Distribution
CCP#5
Microbial
Growth
≤ 4 0C
Shelf-life
14 days
Check the
storage
temperature and
shelf-life and
record keeping
Routinely
Check the time
and
temperature
Retain or reject
based on
product testing
by panelist
Temperature
log, Delivery
report
QAM and
Production
Manager

FOOD REGULATION AND COMPLIANCE
 Few Important terms
 Act
 First Bill is passed either by Parliament or by State Legislative Asssembly and thereafter
when it is finally signed by Hon'ble President/Governors, thus, Act is enacted.
 Rules
 After enactment of Act Rules are framed thereunder for specific Act to control as well as
make it workable
 Regulation
 Further Regulations/ Orders were preparepared by the Department Concerned for better
understanding and control in the preview of Act and Rules prepared under Constitution of
India.
 Ordinance
 a law or regulation made by a city or town government / a law set forth by a governmental
authority; specifically : a municipal regulation

RULES AND LAWS RELATED TO FOOD SAFETY
MANAGEMENT
1. The Bangladesh Pure Food Ordinance, 1959
2. The Bangladesh Pure Food Rules, 1967
3. The Food Grain Supply Ordinance, 1956
4. The Radiation Protection Act, 1987
5. The Iodine Deficiency Disorders (IDD) Prevention Act, 1989
6. Fish and Fish Product Rules, 1997
7. The Animal Slaughter and Meat Control Ordinance, 1983
8. The Pesticide Ordinance, 1971
9. Destructive Insects and Pests Rules, 1966-1989
10. Agricultural Products Market Act, 1950
11. Fish Protection and Conservation Act, 1950
12. The Marine Fisheries Rules, 05/09/1983
13. Procurement Specifications, Ministry of Food, Rice, Rice Mill Control
Order
14. The Bangladesh Standards and Testing Institution Ordinance, 1985
15. The Essential Commodity Act, 1990

OTHER RELATED LAWS AND REGULATIONS
 Bangladesh-New Food Safety Laws 17 Jan 2010
 The cantonments Pure Food Act-19/07/1966
 The Food (Special Courts) Act-13/11/1956
 The Seed Rules-08/03/1998
 The Breast-Milk Substitutes Ordinance-24/05/1984
 The importers, Exporters and Indenters Order-
22/10/1981

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