HAZARD ANALYSIS WORKSHEET

FRESH EPAL FRUIT JUICE

Is this Is this step

Potential hazard introduced, potential WHY a critical
Ingredient or Preventive measures of the
controlled or enhanced at this hazard is Justification for decision on control
Processing step significant hazard
step significant? previous column point
(YES/NO) (YES/NO)
Biological
no Unlikely to occur GAP No
Farm Bird, insect
1.
Growing Chemical
Physical
Biological Reduce potential damaged Remove visually mould and it is
yes Yes
Damaged and Rotten apples apples tree pick apples
Farm Chemical
2. Residue will have adverse Culling
Harvesting Chemical contamination yes Yes
effect GAP
pestiside
Physical
Biological
Farm Chemical Controlled by pre-requisite
3. no Temperature <10 C No
Bulk storage Mould contamination programs
Physical
Biological
Transportation Chemical Controlled by pre-requisite
no GAP No
4. Bulk Chemical contamination programs
transportation Physical Controlled by pre-requisite
no GAP No
Damaged apples programs
 Biological Obtain supplier guarantee letter
Vegetative and protozoan enteric batches containing
yes Damaged and rotten apples. Yes
pathogens (i.e., E.coliO157:H7 materials are checked for
andCryptosporidium parvum) integrity and order specifications
Factory Supplier guarantee (apples
5.
procurement harvested to exclude fallen fruit)
Chemical
yes May have adverse effect and culling or trimming Yes
High level of patulin, pestiside
defective (i.e., moldy, rotten,
bruised and damaged) apples.
Physical
Biological to remove rotten apple flesh,
-Remove visually mouldy apple
Pathogen growth, contamination yes and patulin, from the fruit Yes
-using high-pressure water
Factory sorting Unlikely occur because of tested every
6. Chemical
and washing No daily in house monitoring on quarter for coliforms by a No
Water’s chlorine level
water source supply certified external laboratory
Physical
no To eliminate foreign particles No
Foreign particles
Biological prevent a build-up of mouldy
No No
Pathogen growth apple waste
Factory presses are cleaned regularly
Chemical Controlled by pre-requisite
7. Milling and no No
Chemical patulin contamination programs
pressing
Physical
no Filteration will trap it No
Metal fragment
Biological Yes
mould yes
Factory Chemical
8. Yes May have adverse effect
filteration Chemical patulin
Physical Screen are checked and if
yes May have adverse effect Yes
Metal fragment necessary replace it
 Biological Controlled by pre-requisite
yes
programs
Addition of Act as preservative
Chemical Correct weighing and
9. sulphite and no No
Chemical sulphite, patulin addition of sulphite
water Carried from previous step
Physical Controlled by pre-requisite
programs
Biological
Yes To destroy any pathogens Plate heat exchanger Yes
Pathogen growth
Factory
10. Chemical Inactive spore as patulin not
pasteurization Yes Yes
Chemical patulin production destroyed by heat
Physical
Biological Controlled by pre-requisite
no No
Pathogen growth programs
Factory aseptic Chemical Controlled by pre-requisite
11. no No
filling Chemical patulin production programs
Physical Controlled by pre-requisite
yes Yes
plastic programs
Biological Product likely spoils if Maintain coldroom temperature
yes Yes
Pathogen growth temperature not controlled well at <18C
Factory
Chemical
12. Storage &
N/A
dispatch
Physical
N/A
 HACCP Plan Summary

Hazard to
Critical be Critical limits Monitoring
Control Process addressed for each Corrective
Verification Records
Point step in control action
(CCP) HACCP measure What How frequency who
plan
Remove mouldy
Sampling to
<1% visibly and damaged
determine
Farm mouldy apples Visual Each Trained Farm
CCP1 Mould Discard characteristic
harvesting apples Avoid trash and soil observation harvest supervisor record
quality of
contamination
apples
-<1% visibly -Remove mouldy -Visual -QC manager
-Discard or re-
mouldy apples observation of Review all
sort -
apples samples records within
Adjust Operator
Factory -Leach patulin from one week of
Mould Twice per inspection log %
sorting -Critical apples. Remove -Time of Quality preparation
CCP2 and production procedure reject
and soaking time rotten parts of fruit soaking step; control staff
patulin run
washing and pressure containing patulin regular check -Sample for
-Repeat the -Factory
of spray with pressure of water spray presence of
washing step record
system spraying pressure patulin
quarterl
 Un-block
Review
Size and /replace filter
screens
Patulin, quality of Remove patulin in Re-filter juice
Laboratory Every monitoring Factory
mould particles particles
test batch Production record record
CCP3 Filtration remaining Remove the
emplyee
Metal Screen is Integrity of the metal or if
visual daily Review
fragment intact screen necessary
maintenance
replace the
record
screen
Act as
Quality
Shelf live preservative Check and
assurance
Addition and monitor amount
Reduce pathogen Laboratory Every Production personel Factory
CCP4 of sulphite pathogen pathogen of the sulphite
level test batch emplyee review the record
and water contamina contamination added
record of
tion in acceptable
samples
level
Re-pasteurise?
-
and adjust the
-Automated Continuou
temperature
readout s
temperature recording
Adjust the
-Correct recorder with Verification Factory
Temperature of the pump to deliver
time/Tempera hourly of the heat record
Mould juice >6s
pasteurizat ture Visual visual Pastuarise process
CCP5
ions check of check operators Tempera
patulin - Set pump speed to Clean and
->160 F for positive of record. Calibration of ture
5 to deliver > 6 s sanitize
6s displacement the pump record
all equipment
pump at -Daily at
post-
set speed beginning
pasteurization
of
production
CCP
determination
Question 1 Question 2 Question 3 Question 4 CCP
Do preventive measures Is the step Could Will a subsequent
exist? specifically designed contamination step eliminate Yes or no
No- not a CCP to eliminate or reduce with identified identified hazards
the likely intake hazards occur in or reduce the likely
However, if preventive occurrence of the excess of occurrence to an
Process step Hazard
control measures are hazard to an acceptable levels? unacceptable level?
required to ensure safety acceptable level?
then modify step, product No – not a CCP No – CCP
or process. No – to Q3 Yes – to Q4 Yes – not a CCP
Yes - CCP
Yes – to Q2
Farm
Mould Yes Yes Yes
Harvesting
Factory
Mould and
sorting and Yes Yes Yes
patulin
washing
Patulin, mould
Filtration Yes Yes Yes
Metal fragment
Addition of Shelf live and
sulphite and pathogen Yes No Yes Yes Yes
water contamination
pasteurizations Mould, patulin Yes Yes Yes