This document provides a Hazard Analysis and Critical Control Point (HACCP) plan for the production of apple jam. It begins with an introduction to jam and HACCP principles. A flow diagram of the apple jam production process is presented. Potential hazards at each step are identified, such as microbial contamination or chemical residues. Critical control points are established where limits can be set and monitored to prevent hazards, such as maintaining time/temperature standards during boiling. Record keeping, validation, and staff training procedures are discussed to ensure proper implementation and maintenance of the HACCP plan. The document aims to apply HACCP principles to identify, control, and document food safety hazards for the production of a shelf-stable apple jam product.
The Safety measures of Pineapple Jam can be improved, maintained and sustained by implementing HACCP Plan, as it covers all aspects during raw pineapple conversion to Pineapple Jam
Control of temperature and time duration in boiling unit and Quantity of Pectin and Temperature during Gelatinization are CCPs.
To obtained good hygienic Pineapple Jam these CCPs must be controlled and HACCP Plan must revised every year.
The Safety measures of Pineapple Jam can be improved, maintained and sustained by implementing HACCP Plan, as it covers all aspects during raw pineapple conversion to Pineapple Jam
Control of temperature and time duration in boiling unit and Quantity of Pectin and Temperature during Gelatinization are CCPs.
To obtained good hygienic Pineapple Jam these CCPs must be controlled and HACCP Plan must revised every year.
Hazard analysis critical control point (haccp)Allwyn Vyas. G
Hazard analysis and critical control points or HACCP is a systematic preventive approach to food safety from biological, chemical, and physical hazards in production processes that can cause the finished product to be unsafe, and designs measurements to reduce these risks to a safe level.
What is food processing and their need in food industries, what are post-harvest losses and why to minimize them, post-harvest technology, types of food processing, the effect of food processing on food nutrients and traditional versus modern methods used in processing
Thermal processing is defined as the combination of temperature and time required to eliminate a desired number of microorganisms from a food product.
The term "thermal" refers to processes involving heat.
Heating food is an effective way of preserving.
The basic purpose for the thermal processing of foods is,
to reduce or destroy microbial activity,
reduce or destroy enzyme activity,
and to produce physical or chemical changes,
to make the food meet a certain quality standard.
This presentation is Part 5 of a training program on Food Safety Practices for the Aquaculture Industry by Michigan State University, on 22 April 2013.
Hazard analysis critical control point (haccp)Allwyn Vyas. G
Hazard analysis and critical control points or HACCP is a systematic preventive approach to food safety from biological, chemical, and physical hazards in production processes that can cause the finished product to be unsafe, and designs measurements to reduce these risks to a safe level.
What is food processing and their need in food industries, what are post-harvest losses and why to minimize them, post-harvest technology, types of food processing, the effect of food processing on food nutrients and traditional versus modern methods used in processing
Thermal processing is defined as the combination of temperature and time required to eliminate a desired number of microorganisms from a food product.
The term "thermal" refers to processes involving heat.
Heating food is an effective way of preserving.
The basic purpose for the thermal processing of foods is,
to reduce or destroy microbial activity,
reduce or destroy enzyme activity,
and to produce physical or chemical changes,
to make the food meet a certain quality standard.
This presentation is Part 5 of a training program on Food Safety Practices for the Aquaculture Industry by Michigan State University, on 22 April 2013.
A method known as 'current Good Manufacturing Practice (GMP) is used to guarantee that goods are consistently manufactured and monitored in accordance with quality standards. Good Manufacturing Practices is intended to reduce any production-related hazards associated with pharmaceuticals that cannot be avoided via evaluating the finished product.
Why is GMP crucial?
In addition to being a health risk, low-quality medications cost both governments and individual customers money.
Medicines of poor quality can harm one's health.
Unintentionally added harmful chemicals may be found in low-quality medications.
A medication won't have the desired therapeutic outcome if it contains little to no of the advertised component.
Describe GMP.
A method known as 'current Good Manufacturing Practice (GMP) is used to guarantee that goods are consistently manufactured and monitored in accordance with quality standards. It is intended to reduce any production-related hazards associated with pharmaceuticals that cannot be avoided via evaluating the finished product. The primary dangers include unanticipated product contamination, which can harm health or even result in death; inaccurate labelling on containers, which might result in patients receiving the wrong medication; and an inadequate or excessive amount of active component, which can lead to ineffective therapy or negative consequences. GMP covers every aspect of production, including raw materials, space, and tools, as well as employee training and personal hygiene. Every process that might have an impact on the final product's quality requires specific, written procedures. To be there
If there is a quality control laboratory, is GMP still required?
Yes. Quality cannot be tested into a product after it has been produced; it must be built in during the manufacturing process. GMP guards against mistakes that can't be caught by final product quality control. Without GMP, it is impossible to ensure that each individual dose of a medication is of the same calibre as the sample doses examined in a laboratory.
Can businesses afford to adopt GMP?
Yes. Making cheap items does not result in cost savings. In the long run, fixing mistakes after they have been committed is more expensive than avoiding them in the first place. GMP aims to stop mistakes from occurring. Implementing GMP is a financial investment in premium drugs. In addition to helping the pharmaceutical business and healthcare professionals, this will enhance the health of the individual patient and the community. Poor quality pharmaceutical production and distribution damage the reputation of the company, the public health system, and private health care.
WHO strives to improve GMP
WHO GMP regulations are accessible online. Please get in touch with the WHO representative in your nation, your WHO regional office, or WHO headquarters in Geneva if you need additional information.
In addition, an impartial, independent body should periodically carry out a thorough verification of the HACCP system. These authority may reside inside or outside the food operation. In addition to an on-site inspection of all flow diagrams and the pertinent data from the plan’s execution, this should include a technical evaluation of the hazard analysis and each component of the HACCP plan
To guarantee that the identified risks are avoided, handled, or reduced to tolerable levels, each CCP will comprise one or more control measures. Each control measure has one or more crucial limitations that go along with it. Temperature, time, physical dimensions, humidity, moisture content, water activity (aw), and others may all serve as critical constraints.
The preparation of beef patties is one instance (Appendix B). The procedure need to be planned to guarantee the creation of a secure product. Enteric infections, such as salmonellae and verotoxigenic E. coli O157:H7, were deemed to be the most serious biological dangers for cooked pork patties. Additionally, it is during the cooking process that control may be used to lower the intestinal pathogens to a tolerable level. It is essential to have accurate knowledge of the anticipated concentration of pathogens in the raw patties, their heat tolerance, the variables influencing how well they heat up, and the section of the patty which warms the slowest in order to guarantee that an appropriate level is routinely obtained.
Through the study and management of biological, chemical, and physical risks throughout the production, handling, and distribution of raw materials as well as the manufacture, distribution, Food safety standard and HACCP and consumption of finished goods, HACCP is a management strategy that addresses food safety.
HACCP is a management method that addresses food safety by analyzing and controlling biological, chemical, and physical risks throughout the production, handling, and distribution of raw materials as well as the manufacture, distribution, and consumption of finished goods.
Implementation of hazard analysis critical control point (HACCP) in crabmeat ...INNS PUBNET
Blue Swimming Crab or Portunus Pelagicus is one of the most valuable fisheries commodities of Indonesia. The crab is very potential fisheries product due to its high demand on global market. On the other hand, the crab is a perishable product that is likely to spoil and decay. Therefore, it is important to apply quality assurance system to guarantee the food safety of the crab. Hazard analysis critical control points (HACCP) is a world-recognized, effective, and preventive food safety management system. This study aims to determine how the implementations of quality control in terms of the HACCP system in crabmeat plant in Cirebon, West Java, Indonesia. Method of this research was observation in production line of crabmeat pasteurized processing and interview towards employees and management. HACCP model was set up based on the actual conditions in the plant. The HACCP system was based on seven principles as follow: 1. Conduct a hazard analysis. 2. Determine the critical control points (CCPs). 3. Establish target levels and critical limit(s). 4. Establish a system to monitor the CCPs. 5. Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control. 6. Establish procedures to verify that the HACCP system is working effectively. 7. Establish documentation concerning all procedures and keep records. The most important identified CCPs were receiving, metal detecting, seaming, pasteurizing, chilling and chill storage. Based on this research and findings, the authors recommend for implementation of HACCP system in crabmeat pasteurized processing industries.
Kiribati Agritourism Policy Setting Workshop 2019
Workshop Policy Setting for Improved Linkages Between Agriculture, Trade and Tourism: Strengthening the Local Agrifood sector and Promoting Healthy Food in Agritourism.
Workshop Programme Organised by the Government of Kiribati and Kiribati Chamber of Commerce and Industry
In collaboration with the Pacific Community, CTA, PIPSO and SPTO.
Tarawa, 15th -16th January 2019, Kiribati
Venue: RAK Boardroom, Antebuka
Hotel management involves overseeing all aspects of a hotel's operations to ensure smooth functioning and exceptional guest experiences. This multifaceted role includes tasks such as managing staff, handling reservations, maintaining facilities, overseeing finances, and implementing marketing strategies to attract guests. Effective hotel management requires strong leadership, communication, organizational, and problem-solving skills to navigate the complexities of the hospitality industry and ensure guest satisfaction while maximizing profitability.
Vietnam Mushroom Market Growth, Demand and Challenges of the Key Industry Pla...IMARC Group
The Vietnam mushroom market size is projected to exhibit a growth rate (CAGR) of 6.52% during 2024-2032.
More Info:- https://www.imarcgroup.com/vietnam-mushroom-market
Hamdard Laboratories (India), is a Unani pharmaceutical company in India (following the independence of India from Britain, "Hamdard" Unani branches were established in Bangladesh (erstwhile East Pakistan) and Pakistan). It was established in 1906 by Hakeem Hafiz Abdul Majeed in Delhi, and became
a waqf (non-profitable trust) in 1948. It is associated with Hamdard Foundation, a charitable educational trust.
Hamdard' is a compound word derived from Persian, which combines the words 'hum' (used in the sense of 'companion') and 'dard' (meaning 'pain'). 'Hamdard' thus means 'a companion in pain' and 'sympathizer in suffering'.
The goals of Hamdard were lofty; easing the suffering of the sick with healing herbs. With a simple tenet that no one has ever become poor by giving, Hakeem Abdul Majeed let the whole world find compassion in him.
They had always maintained that working in old, traditional ways would not be entirely fruitful. A broader outlook was essential for a continued and meaningful existence. their effective team at Hamdard helped the system gain its pride of place and thus they made an entry into an expansive world of discovery and research.
Hamdard Laboratories was founded in 1906 in Delhi by Hakeem Hafiz Abdul Majeed and Ansarullah Tabani, a Unani practitioner. The name Hamdard means "companion in suffering" in Urdu language.(itself borrowed from Persian) Hakim Hafiz Abdul Majeed was born in Pilibhit City UP, India in 1883 to Sheikh Rahim Bakhsh. He is said to have learnt the complete Quran Sharif by heart. He also studied the origin of Urdu and Persian languages. Subsequently, he acquired the highest degree in the unani system of medicine.
Hakim Hafiz Abdul Majeed got in touch with Hakim Zamal Khan, who had a keen interest in herbs and was famous for identifying medicinal plants. Having consulted with his wife, Abdul Majeed set up a herbal shop at Hauz Qazi in Delhi in 1906 and started to produce herbal medicine there. In 1920 the small herbal shop turned into a full-fledged production house.
Hamdard Foundation was created in 1964 to disburse the profits of the company to promote the interests of the society. All the profits of the company go to the foundation.
After Abdul Majeed's death, his son Hakeem Abdul Hameed took over the administration of Hamdard Laboratories at the age of fourteen.
Even with humble beginnings, the goals of Hamdard were lofty; easing the suffering of the sick with healing herbs. With a simple tenet that no one has ever become poor by giving, Hakeem Abdul Majeed let the whole world find compassion in him. Unfortunately, he passed away quite early but his wife, Rabia Begum, with the support of her son, Hakeem Abdul Hameed, not only kept the institution in existence but also expanded it. As he grew up, Hakeem Abdul Hameed took on all responsibilities. After helping with his younger brother's upbringing and education, he included him in running the institution. Both brothers Hakeem Abdul Hameed and Hakim Mohammed
Roti Bank Delhi: Nourishing Lives, One Meal at a Time
Jam HACCP Plan
1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/330533644
HACCP Plan for Food Products (Apple Jam)
Presentation · January 2019
DOI: 10.13140/RG.2.2.16340.24961
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2. 1
Essay on
HACCP Plan for Apple Jam
Submitted by
Krishnakumar Thulasimani
Course Module: Food Safety
3. 2
LIST OF CONTENTS
S.No Contents Page No.
1. Abstract 1
2. Introduction 1
3. HACCP – general principles and steps 1
4. Elaboration of HACCP for apple jam 4
5. Traceability, validation, verification and documentation 6
6. Elaboration on microbial hazards- sources, proliferation, effect of microbes or
its toxin on final consumer
9
7. Monitoring and use of rapid methods 10
8. Conclusion 11
9. References 11
4. 3
Abstract
Apple jam is a gelled product made by boiling crushed apples with sugar and water.
Production of such a ready-to-eat food which is usually not refrigerated requires that all food safety
risks are eliminated. The use of the HACCP system has thus been applied as food safety tool. These
both ensure production of safe products and compliance with basic regulations on food hygiene.
The major sources of contamination, and the possible pathogens and their toxins such as patulin
form moulds, Listeria monocytogenes and E. coli must be analysed and effective preventive
measures implemented.
Introduction
Several definitions for jam are available depending on who is doing the definition (i.e.
background of the person). From a legal standpoint, the EU directive on preserves (EC, 2001)
defines jam as '... a mixture, brought to a suitable gelled consistency, of sugars, the pulp and/or
purée of one or more kinds of fruit, and water... the quantity of pulp and/or purée used for the
manufacture of 1000g of finished product must not be less than 350g as a general rule.
In general however it is accepted that jam is produced by taking mashed or chopped fruit
pulp and boiling it with sugar and water. It is also a widely accepted notion that jams are from the
pulp and juice of one fruit, rather than a combination of several fruits. The traditional understanding
of jam was that of a self-preserved cooked mixture of fruit and sugar. The degree of preservation
related to the final water activity of the product but there are other factors affecting spoilage. These
include soluble solid content, pH and titratable acidity, as well as other unknown intrinsic indices
related to the fruit used (Broomfield, 2001). Commonly when the mixture reaches 105o
C, the acid
and pectin in the fruit react with the sugar forming the gel which sets on cooling.
Apple jam will thus be made of chopped apple fruit and apple purée and sugar. The use of
apple is advantageous because apple is on of the few non-citrus fruits known to have a high level of
natural pectin, thus the production can proceed without addition of commercial pectin. Its acid
levels are however low, but can be supplemented by natural screened lime juice. The use of the term
'organic' in food circles is gaining more grounds in this age as people become conscious of what
they eat. Organic has generally been used to refer to an ecological system that at its core relies on
health rich soil to produce strong plants that resist pests and disease; it generally prohibits the use of
pesticides, genetically modifies organisms (GMO), synthetic preservatives and
antibiotics/hormones. In the production of food products such as jam, there is ''... the restriction of
the use of food preservatives, of non-organic ingredients with mainly technological and sensory
5. 4
functions and of micronutrients and processing aids, so that they are used to a minimum extent (EC,
2007). Also, processed foods are only allowed to be labelled organic if all or almost all the
ingredient of agricultural origin is organic. The hazard analysis and critical control point (HACCP)
system has over the years become one of choice as reliable way to ensure safety at all levels in the
food chain. Thus its implementation in the production of a ready-to-eat product such as apple jam
will be most appropriate.
HACCP- Principles and Steps
Since its initial use by the Pillsbury Company in the 1950's as part of the food safety efforts
in the NASA/ US military space program, HACCP has gradually proven to be the food safety tool
of choice in most food establishments. It has been recognised and approved for use in the food
industry by national and international bodies such as the NACMF of the US, WHO/FAO (Codex),
ICMSF, as well as several governments as the basis for legal framework on food safety. The EU
regulation 178/2002 (EC, 2002) requires entities in the food chain to have a safety system in place
based on HACCP. The ISO standard ISO 22000 on food safety is also largely built on the principles
of HACCP.
HACCP is an analytical tool that enables a food entity to implement and maintain a system
for ensuring food safety. It generally involves assessment of all steps in the particular
manufacturing process, while identifying those steps that have a major effect on the safety of the
food (Burrow, 2001). The identification of the eventual critical control points (CCP) along with
monitoring and control parameters is then the results of the analysis and culminates in the creation
of the safety system.
The HACCP system is based on a universally recognised set of seven principles that are used to
design a safety plan for the food. These principles:
1. Conduct hazard analysis
2. Determine CCP
3. Establish critical limits
4. Establish monitoring procedures
5. Establish corrective action procedures
6. Establish verification procedures
7. Establish record-keeping and documentation procedures
(Ali, 2004)
6. 5
However the Codex Alimentarious Commission has created a logic sequence for the
implementation or application of HACCP. This sequence essentially adds 5 preceding steps to the
seven principles in the implementation phase. These steps are:
1. Assemble a HACCP team
2. Describe the food product that the HACCP plan will address
3. Identify the intended use of food product
4. Construct a flow diagram of the process that is used to produced the product
5. Conduct on-site verification of the process flow diagram
(Codex, 1997).
HACCP for Apple Jam Plant
In the light of the above, the paragraphs below will try to follow the codex logical sequence
to elaborate on a HACCP system for an apple jam production plant.
HACCP Team
A team of company personnel with a good knowledge of food safety management is
assembled. In some cases there may be the need to include a consulting expert in the initial process
but this person may not be a permanent member of the team. The team will typically include the
Quality Manager (team leader), Production Manager/Supervisor, a senior member of production
staff and the Maintenance Manager. The team is responsible for the planning, implementation and
general documentation of the HACCP system. Documentation of general management
responsibility and support for system should be clear and evident in the general quality manual of
the company as the quality policy. Management support is crucial for the success of such a program.
The Product (Apple Jam)
As explained in the introductory section, apple jam is a gelled ready-to-eat product. It may
be used as spread for bread and also as filling for other pastries and bakery products. When packed
in the normal glass containers, the product should have a shelf life of about 4 months prior to
opening. It has a total soluble solids content of about 66% (refractometer solids), pH of between 3.5
and 3.8, and water activity of 0.76-0.78. After opening the product ideally should be refrigerated at
5o
C although this may not be necessary. It is however important that the product is tightly closed at
all times.
7. 6
Figure 1: Flow Diagram of Apple Jam Production
Receipt of Raw apple &Sorting
Washing and Cleaning
Preprocessing
(Crushing)
Mixing in vessel
Water Addition
Sucrose source
Screening
Boiling in Chamber
Holding in Vessel
(allow setting)
Filling into Jars
Labelling &Holding
Dispatch
Lime
Juice
Addition
Washing and
Sanitizing of Jars
8. 7
An on-site verification of the diagram is made by the HACCP team.
Prerequisite Program
It is generally accepted no HACCP plan can be effectively rolled out without a well established
HACCP prerequisite program in place. Prerequisite programs or good manufacturing practices
(GMP's) are programs that ensure general hygiene and sanitation in the plant. Prerequisite programs
may come under broad categories such as:
Chemical control
Equipment maintenance and sanitation
General sanitation and cleaning
Pest control
Personnel training on hygiene and related issues
Transportation: receiving, storage and shipping of material and products
Others.
Detailed manuals for the execution of all these functions should be available and strictly followed.
HACCP Plan Summary
Each of the steps involved in the production is analysed by the HACCP team and all
possible hazards identified. Hazards are further streamlined based on probability of occurrence and
consequence of customer exposure in the event of lost of control. Based on such a matrix and using
a typical CCP decision tree (Ali, 2004), the CCP's in the process are identified. Critical limits for
these CCP's were set for the identified possible hazards based on available scientific literature and
research information. Monitoring procedures are also elaborated to ensure that the parameters are
always within the set limits. Corrective action procedures are also clearly stipulated on how to
handle the production or product in event of limits being exceeded (non-conformity).
Table 2 below shows a summary of the above processes and the resulting basic HACCP plan.
Validation, Verification and Documentation
As part of the HACCP system, a documented procedure for validation of the effectiveness of
control measures and monitoring and measuring systems must be in place. Also internal audits by
qualified personnel of the HACCP team are done monthly to ascertain the implementation and
effectiveness of the system. Such audits are planned according to documented procedures and
schedules by management and the HACCP team. Records of such audits are submitted to
management for review and corresponding action.
9. 8
Documentation of the entire system and the day to day activities done in implementation is very
important in a HACCP system. For instance at the top any document in the system is control box
showing the function and line of authority such as one below.
Table 1. A control box
THE COMPANY- (document type) Revision: x
(Document Tile) Date: xx/xx/xxxx
The Company- aaa-cc-x Authorized by:
Page x of z
10. 9
Table 2: HACCP Plan Summary for Apple Jam Production
Step (CCP) Hazard Critical
Limits
(Parameters)
Control Measure Monitoring System
Method Frequency
Corrective
Action
Responsibility
(Authority)
Record
Receipt of
fresh apple and
sorting
Foreign bodies
and mould
from rotting
fruits.
Pesticides
residue
Presence of
mould
infestation in
apple lot.
Assessment of
lot (accept or
reject batch)
Supplier
assessment.
Certificate of
conformance
from suppliers
Visual
inspection
Presence of
signed
certificate from
supplier
Each batch
intake of
ingredients
Appropriate
action with
supplier (reject
lot)
Purchasing
Manager
PUX 1
Water Source
screening
Presence of
excess ions
(chlorine) and
off flavours.
High bacteria
count
pH level of 6
to 8 and
chloride level
of 250mg/lit
Sensory and on-
site kit test (for
chlorine)
Scheduled
Microbiological
analysis of water
samples
Tasting and
smelling.
Instant test kit
results
Daily Inform water
suppliers.
Regulate
chlorine
control system
(in-house)
Quality
assurance
officer
QAW1
11. 10
Boiling of Jam
Mixture
Survival of
bacterial
spores, moulds
and toxins
Temperature
of 105o
C for
15 minutes
Measurement
and observation
of temperature
throughout
boiling
Temperature
measurement
Each batch Rework- reheat
over extended
period
Production
Supervisor
PDX 1
Holding of Jam Cross
contamination
by bacteria and
mould in air
Functioning
air pressure
system in
holding room.
Temperature
of 54o
C
Monitoring of
air pressure
control system
in holding room
Zoning of
holding room as
high rick zone
(using colour
such as red)
Measuring of
holding
temperature and
cooling rate.
Temperature
measurement.
Checking of
filter in air
system
Continuous per
batch
(temperature)
Daily (filters)
Rework
Hold affected
batch till
confirmation
by laboratory
analysis.
Production
Supervisor.
Quality
assurance
officer
PDH 2
QAH 2
Container
cleaning and
Cross
contamination
Negative
random ATP
Random ATP
swab of
Visual
inspection and
Twice per
batch.
Quarantine
suspected
Production
Supervisor
PDC 3
12. 11
Filling
(packaging)
from the
containers.
Improper
sealing.
Cleaning agent
residue
swab of
containers.
Low cleaning
agent
concentration
in rinse water.
Pass random
sealing test
containers and
covers.
Periodic /batch
of cleaning
agent
concentration in
rinse water.
Sealing
efficiency test.
ATP kit swabs.
On-site rinse
water
concentration
measurement.
Sealing
efficiency test
product,
pending
laboratory
analysis
results.
Quality
assurance
officer
QAC 3
13. 12
Elaboration on Microbiological Hazards and Prevention
Generally the important bacteria worthy of note in fruit products is Listeria monocytogenes
which is a common contaminant in the food processing plant, though the faecal coliform
Escherichia coli may also be important. Control of microbial hazards should thus include ensuring
that water supply is free from contamination and that hygiene and sanitation programs for premises
and staff are strictly implemented, as these may be routes for contamination (Beatie and Wade,
2001).
For the raw apple, the major food safety problem is that of mycotoxins produces by
contaminating mould such as Penicillium expansum. This fungus produces the blue mould rot with
the inherent toxin patulin. Patulin is also known to be produced similar moulds that grow on apple
jam in storage, especially when exposed in the home after initial opening (Lindroth et al, 1978,
Lindroth and Niskanen, 1978). The important spoilage organism for apple jam is the yeast
Zygosaccharomyces rouxii, but Toruluspora delbrueckii may also be found. These fungus cause
spoilage by fermenting the jam, with production of gas. The conditions thus created may invite
other pathogens such as lactic acid bacteria and others to invade the jam, causing further disease on
consumption.
Raw Materials
Especially with regards to organically produced apples for the jam, which are not treated
with fungicides, contamination by mould and the subsequent production of patulin is the major food
safety index. Care should be taken in the initial receipt step to ensure that the apple lot is in good
condition, free of rotting/rotten fruits as much possible. Any fruit observed not to be of sound
quality should be removed. Sorting should continue during the washing process. Re-use of water for
later washing should be avoided unless substantial treatment regimes have been applied. With good
storage conditions, the sugar should not be a source of worry with respect to pathogenic infection,
provided certification of conformance to GMP is received form supplier. Care should be taken to
avoid wetting and storage contamination. This could be due to the presence of such pests as ant,
cockroaches and rodents (rat and their droppings).
The water source is very important in the manufacturing environment as it is used in the pre-
processing steps, the cleaning and sanitation of the plant, as well as being a composite part of the
final product. Samples of the water should be taken periodically for laboratory analysis to ensure
bacteria counts are as low as possible. Positive result trends should be investigated and required
14. 13
action taken. It will be advisable to pass water to be incorporated into the jam pass through a filter.
This filter must be checked frequently for efficiency and soundness. As a general rule (of thumb),
water used in the processing plant should be of drinking water quality.
Processing Equipment and Personnel (Hygiene).
Equipment used in the manufacture of jam and other preserves have been known to harbour
certain spoilage yeast unless thoroughly freed of sugar residues and then disinfected. The common
spoilage yeast of jam, Z. rouxii, may be enriched and carried from one production run to the next if
these ‘sugar-rich localities’ in the plant are not eliminated (Seiler, 1977). Apart from being the
growth substrate for yeast, these areas may also attract pests such as insects and rodents with the
pathogens they carry around.
Faecal contamination and the introduction of soil may bring bacteria such as E. coli,
Salmonella spp. and L. monocytogenes. The elimination of these bacteria is paramount in any food
production establishment. Important sources of such contamination include pests on the plant,
personnel clothing and footwear as well as improper general hygiene. The inclusion of an integrated
pest management program in the pre-requisite program is thus stressed here. The highest level of
plant and personal hygiene should be practised by personnel, who should be adequately educated on
the need for this and measures and the consequences of default. An important tool that may be used
to reduce the spread of contamination is zoning of the processing area. The creation of colour coded
higher levels/zones will thus be used in this plant. Personnel must also as a rule be made to wear
appropriate clothing including hair covering. Foot baths and other such facilities for hand washing
and other hygiene practices must be provided and sited at vantage points where their use is crucial
to prevent contamination.
Packaging and Storage (Including Storage at Home after Opening)
The temperature at which filling of the jam is done is important for both quality and safety
reasons. Filling at an elevated temperature ensures jam will set properly in the jar. However an
elevated temperature is also essential to create an environment that excludes air borne bacteria.
Sanitation of the glass jars and covers is to ensure removal of all possible contaminants as the jar
can be important in cross contamination of the product, especially from bacterial spores and some
moulds. Temperature of the washing water and the time of contact should be adequate to have
desired lethal effect on targeted microbes. If a washing trough is used, the water should be
15. 14
frequently changed to avoid concentration of removed contaminants.
After packaging and labelling, handling and storage at less than 5o
C through shipping and
sale display (in supermarkets) should keep jam safe within stipulate shelf life. In the home however,
contamination may occur if precautions are not taken. Growth of moulds and the subsequent
production of patulin in the jam is likely if the jam is not covered properly after initial opening.
Contamination by faecal bacteria such as E.coli and Salmonella are possible if there is negligence in
handling.
Monitoring and Use of Rapid Methods
Monitoring is the scheduled measurement or observation of a CCP for compliance with the
target levels and the specified tolerance ranges established for each control measure. Both on-line
(time temperature) and off-line (soluble solid, pH) measurements are important indications of the
performance of the HACCP system. The use of rapid method that yield results fast enough to allow
decisions to be taken are evolving at a fast rate in the industry. For instance after a cleaning
exercise, the effectiveness of the cleaning may be required, before further processing on the surface.
Rapid test methods are available as ready-to-use kits, for instance ATP-bioluminscence.
These tests examine organic remains on a surface which poses an indirect risk for microbial growth.
ATP-bioluminscence detects ATP from microorganism and organic residues. (Vogel, 2007). These
tests expose results very quickly (within seconds or minutes) making it possible to carry out
corrective actions in response to poor test results, e.g. before production starts. They are sensitive,
safe, easy to use - no specialized knowledge or laboratory facilities are required - and a helpful tool
in monitoring the general hygiene. However, they are not a replacement for microbiological testing,
as they give no evidence of bacterial contamination. (Vogel, 2007)
Characteristics and Effects of Microbes and their Toxins
The mould P. expansum is known to cause extensive damage and loses in apples in countries
such as the US, Canada, France, Sweden and Germany. It produces the blue rot disease in the apple,
with dissightful blue, and brown colouration in advance stages. However even more damaging can
be the ailment caused by the mycotoxin, patulin which it produces. Patulin is generally stable in
acid solutions as low as pH 2, though unstable in alkali. Ingestion of patulin, also known in some
literature as clavacin, penicidin, or myocin C, may produce effects such as abdominal pains, dypsea,
restlessness, and even death, which is preceded by convulsions. Chronic effects may include
ulceration and other carcinogenic effects (Deshpande, 2002). The estimated lethal dose (LD50) for
16. 15
patulin ranges from 25-46mg/kg body weight for oral ingestion to 5-15mg/kg body weight for
intraperitoneal administration. The World Health Organisation has suggested a tolerable weekly
intake of about 7ug/kg body weight (WHO, 1991).
Listeria is ubiquitous in nature, occurring in soil, vegetation and water (Coyle et al, 1984). It
can survive long periods in both soil and plant material. L. monocytogenes can grow in the pH
ranges of 4.3- 9.4 and up to 10% sodium chloride (ICMSF, 1996). It may survive pasteurization at
63o
C for 30 minutes. However exposure at above 72o
C for 15 seconds has been known to destroy it.
Hence in the apple jam, post cooking (105o
C for about 20 minutes) and post filling (54o
C)
contamination will offer more serious Listeria threat. Listerosis is a very serious and often fatal
infection affecting mostly the elderly and immunocompromised. Gastrointestinal illness is one
effect. Listerosis has been known to cause abortions, fatigue, encephalitis, abscesses and meningitis.
In humans, as few as 1000 ingested cells of the bacteria produce diarrhoea, mild fever and malaise
(FDA/CFSAN, 2003). Other faecal coliforms such as Salmonella and E. coli can also cause serious
conditions such as enteric fever which even may be life threatening. As few as 15 cells of
Salmonella for instance can cause illness (FDA/CFSAN, 2003).
Conclusion
The production of organic apple jam, especially on a commercial scale requires careful
planning to ensure that all the food safety issues of concern are adequately addressed. The use of a
well thought through HACCP plan can be a good way to ensure this desired level of food safety.
Apart from fulfilling basic legal requirement on food safety, this can also be used to ensure
customer confidence in the final product on the shelf.
17. 16
References
1. Ali, I. 2004. Food Quality Assurance: Principles and Practices. CRC Press, UK.
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Ashurst. Aspen Publishers, Maryland, USA.
3. Broomfield, R.W. 2001. The Manufacture of Preserves, Flavourings and Dried Fruits. In:
Fruit Processing: Nutrition, Products and Quality Management, 2ed. Eds. D. Arthely and
P.R. Ashurst. Aspen Publishers, Maryland, USA.
4. Burrows, G. 2001. Quality Management System and Hazard Analysis Critical Control Point.
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10. FDA/CFSAN, 2003. Food borne Pathogenic Microorganisms and Natural Toxins Handbook:
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12. Lindroth, S. And Niskanen, O. 1978. Comparison of Potential Patulin Hazard in Home-
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University of Copenhagen.
15. WHO, 1991. Evaluation of Certain Food Additives and Contaminants. 37th
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Joint FAO/WHO Expert Committee on Food Additives. WHO Technical Report Series 806,
Geneva.
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